It’s never been easier to charge an electric car: When charging at a 230-volt power outlet, Bosch’s innovative flexible smart charging cable with integrated control and safety technologies eliminates the need for the bulky in-cable control box known as the “charging brick.” This implies that the flexible smart charging cable, which will make its world debut at IAA Mobility 2021, will be under three kilos in weight. This is around 40% less expensive than traditional charging cords with a control box.

Not only does the high-tech connection save weight, but it also saves room in the trunk. Drivers who wish to be able to recharge from a power socket at home or from a charging station on the road no longer require a second cable because it comes with adapters for Type 2 and domestic outlets. In practice, recharging electric vehicles has never been easier. “Bosch is making electromobility even more customer-friendly with its universal charging cable,” says Dr. Uwe Gackstatter, president of Bosch Powertrain Solutions.

“We want the new cable to be standard equipment for electric vehicles,” says the company. In mid-2022, Bosch plans to begin selling the cable to carmakers and drivers.

The world’s first electric car charging cable with built-in technology for flexible recharging without the need for a control box:

  • The Bosch cable does not require an in-cable control unit and weighs less than three kilos, making it 40% lighter than traditional charging cables.
  • Intelligent: owing to integrated control and safety technologies, the charging power and temperature can be reliably monitored.
  • Adapters for Type 2 and household outlets eliminate the need for a second charging cable, whether at home or on the road.

Bosch offered a sneak peek of their new flexible charging cable in a recent press release, which coincided with its premiere at IAA Mobility in Munich this week.

This flexible smart charging cable, according to Bosch, is the “world’s first” to have integrated universal charging technology without the in-cable charging unit, often known as a “brick.” However, Seth Weintraub of Electrek reported on comparable technology from AeroVironment in 2016.

The new charging cable, according to Bosch, is roughly 40% lighter than brick-equipped cables, weighing around 3 kg (6.6 lbs).

The new cable will also include adapters for charging at both Level 1 and Level 2 AC. The new Bosch cable can connect and offer charge speeds up to 22 kW whether you’re charging at home or at a public station.

Charging at home and on the go at up to 22 kW with a single cable

The three-phase connection permits up to 22 kilowatts of so-called mode 2 and mode 3 AC charging. When recharging at home, the flexible smart charging cable eliminates the need for a wall box. This is exactly what buyers desire. 84 percent of electric car owners in Europe charge their vehicles at home in the evening or overnight (source: new motion EV Driver Survey 2020). The recharging procedure is secure and dependable thanks to the technology built into each of the connectors.

The components for regulating and monitoring the charging power are contained in the type 2 connection at the vehicle end of the cable. The temperature control and a residual current device are housed on the opposite end of the home plug with an adaptor. Even while recharging at a domestic power outlet with up to 2.3 kilowatts of charging power, this prevents overloading or overheating. Before the situation becomes critical, the safety technology deactivates the cable if necessary.

Miniaturization expertise: Bosch reduces technology by three times.

Bosch engineers decreased the size of the electronics components in comparison to prior applications in control boxes to be able to incorporate the control and safety technologies into the small cable connections. They benefitted from the company’s miniaturization expertise, which is continuously improving. Gackstatter adds, “The flexible smart charging cable is a fantastic illustration of how Bosch is leveraging creative high-tech to make everyday life simpler while helping electromobility gain greater adoption.” Furthermore, the new charging cable was created in a relatively short period of time: the development team was able to bring the new charging cable to market maturity in only 18 months.

Innovation leadership: Bosch expands portfolio in electromobility

The Bosch electromobility range now includes a flexible smart charging cable. In this area, the firm adopts a holistic strategy. Bosch offers a wider electrical powertrain range than any other business, ranging from e-bikes to passenger vehicles to construction gear. There are solutions for both battery-electric and fuel-cell powertrains in this range. It also comes with recharge services and a battery-in-the-cloud management solution to help enhance battery performance and lifespan. Bosch has also entered the industry of providing manufacturing equipment for the production of batteries.