First electric car charging cable with integrated technology

September 06, 2021 // By Nick Flaherty
First electric car charging cable with integrated technology
The Bosch 22kW universal EV cable needs no control box and, at under 3kg, weighs a good 40 percent less than conventional charging cables.

Bosch has developed a flexible smart charging cable with integrated control and safety technology that eliminates the wall box at home.

The 3kg cable is 40 percent lighter than conventional charging cables with a control box and comes with adapters for Type 2 and household plugs. This allows drivers to recharge from a power socket at home or from a charging station on the road without needing a second cable.

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“With this universal charging cable, Bosch is making electromobility even more customer-friendly,” said Dr. Uwe Gackstatter, president of the Bosch Powertrain Solutions division. “We want to make the new cable standard equipment for electric vehicles.” Bosch expects to start selling the cable to vehicle manufacturers and drivers in mid-2022.

The three-phase cable enables so-called mode 2 and mode 3 AC charging at up to 22kW at a dedicated charging point with the safety and control integrated into the handle. The technology integrated into each of the plugs makes the recharging process safe and reliable. The type 2 connector at the vehicle end of the cable contains the components for controlling and monitoring the charging power. At the other end, the household plug with adapter houses the temperature control and a residual current device. This ensures that no overloading or overheating occurs even during regular recharging at a household power socket with up to 2.3kW of charging power. If necessary, the safety technology deactivates the cable before the situation becomes critical.

To be able to integrate the control and safety technology into the compact cable connectors, Bosch developers have significantly reduced the size of the electronics components compared to previous applications in control boxes.

“The flexible smart charging cable is a great example


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