Michael Schoenberger, Vice President of Research and Development, Dr. Michael J. Bauer, Executive Vice President and Jan Cappelle, Vice President of Sales and Customer Service Electric vehicles have a long and rich history of their own, with notable advancements and milestones along the way. In recent years, there has been a surge in interest in electric vehicles, driven by their ability to mitigate emissions and decrease reliance on fossil fuels.
Against this backdrop, as part of the Webasto Group, Webasto Charging has emerged as a pioneering force in the electromobility revolution. Webasto Group is at the forefront of electromobility; developing cutting-edge battery systems, electric heating systems, and charging equipment that can cater to current and future mobility needs. Subsequently, the firm offers multiple, innovative e-mobility solutions as part of its commitment to a green future, positioning it as a leader in the transition to a sustainable transportation future.
In 2016, Webasto Group recognized the importance of being involved in the rapidly growing market for electric vehicles and the electrification of the automotive industry. An esteemed automotive supplier with over a century of experience in the sunroof and heating business, it drew on its market leadership and established itself as an innovative system partner for the mobility industry. Armed with its strengths, Webasto Group engaged in multiple discussions with its OEM customers to chart the future strategy for automotive electrification. They confirmed their intent to enter the Electric Vehicle Supply Equipment business, while recognizing the crucial need for a charging infrastructure to support the growth and development of the EV market. Consequently, this concerted effort materialized in the establishment of the business unit, Webasto Charging as part of the larger corporate organization, paving the way for the new venture's inception.
Webasto Charging takes pride in supporting the EV market to facilitate the advancement of the industry and scale the growth of businesses, demonstrating their dedication to the future of sustainable transportation.
Provided is an extensive suite of charging products and solutions, including safe and reliable mobile chargers, state-of-the-art charging stations, and intelligent digital solutions offering from app to backend connectivity including Industrial Charging for ground support equipment at airports and material handling equipment. Its efficient production process covers every step, from initial development, testing, assembly to delivery, allowing it to cater to diverse customer groups with high-quality charging solutions.
“With a focus on expanding our footprint and providing exceptional support to OEM’s, including their customers, we assist in the growth of their EV business by providing comprehensive charging solutions,” says Michael Schoenberger, vice president of research and development at Webasto Charging.
The firm began by supporting key European customers in entering the EV market. When the market expanded, it recognized the potential of the North American market, which was experiencing early growth in 2016. The firm acquired the charging business of a California-based Monrovian company, demonstrating its understanding of the importance of having a U.S. market presence and leading the way in the electrification of the automotive industry.
“This strategic expansion is a proven success, with more than 450,000 charging devices sold globally to OEMs, businesses, and end-consumers, a testament to our commitment to supporting the EV market,” says Dr. Michael J. Bauer, executive vice president at Webasto Charging, headquartered in Germany, and president & chairman at its US subsidy Webasto Charging Systems, Inc.
Mobility of Tomorrow
“We are not only developing a charger but a critical infrastructure important and essential to support the transition to electromobility,” says Jan Cappelle, vice president of sales and customer service at Webasto Charging.
The firm has made significant progress in implementing predictive maintenance, allowing it to preemptively repair or replace critical components in chargers before failure occurs. This approach has led to enhanced cost efficiency and accelerated the deployment of charging infrastructure, which remains a crucial factor in the electrification of the automotive industry.
Webasto Charging has also developed digital backend solutions that can help utilities in reducing stress on the grid, offering features such as load stabilization. A focus on charging and resilience in its supply chain and leveraging the synergies between industries has enabled it to distinguish itself from competitors.
“We are not only developing a charger but a critical infrastructure that is important and essential to support the transition to electromobility”
In addition, the firm’s ownership of the entire product lifecycle management, from market research to local manufacturing, is a powerful value proposition for its clientele. One of the largest market suppliers, it uses industry feedback to continuously improve product quality and enhance customer experience.
It establishes a dependable foundation for compatible charging solutions and develops modular systems with its distinctive blend of automotive and energy expertise. Its advanced electric car charging stations are designed to cater to multiple customers, from individuals to corporations. Various charging solutions can be customized to fit many requirements, and all are compliant with and even surpass industry standards, providing cutting-edge safety features that are implemented worldwide.
In addition, the safety features of Webasto’s charging stations are designed according to principles like automotive and industry functional safety. This ensures the charging stations meet the highest safety standards in all regions, regardless of regulatory requirements.
Client Successes Drive Sustainability
Webasto Charging was tasked with a project by a client with the vision to allow one vehicle to charge another, known as V2V or vehicle-to-vehicle charging. Through minor modifications and collaboration with the OEM, the firm repurposed an existing feature and quickly developed the project while ensuring compliance with safety regulations and aligning with the OEM’s requirements. This enabled the OEM to offer their customers a safe and functional vehicle-to-vehicle emergency charging feature. Throughout the project, Webasto prioritized open communication with the client and worked with them to create a product that met all safety standards.
In another instance, a digital use case, Webasto worked with a European customer who imports electric vehicles and distributes them to different European dealers. The cars arrived with empty batteries, so the firm integrated the charging devices into the customer’s ERP system.
This strategic expansion is a proven success, with more than 450,000 charging devices sold globally, a testament to our commitment to supporting the EV market
The charging station identifies a vehicle’s brand and the customer’s desired battery charge level. For instance, the system is programmed to determine optimal charging levels for the battery, which may be 40 or 60 percent. The ERP system tracks energy use and invoices the customer or dealer. This innovative business model integrates the charging process with the invoicing system, creating a seamless and foolproof solution that eliminates the possibility of misuse. It uncovers new opportunities beyond hardware by enabling a streamlined invoicing process for energy consumption.
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With a focus on expanding our footprint and providing exceptional support to OEMs, including their customers, we assist in the growth of their EV business by providing comprehensive charging solutions
Innovation Fuels the World of Mobility
Webasto Charging’s focus on innovation has led to the development of new products and services, as well as digital backend solutions and predictive maintenance capabilities. Its investment in research and development has also resulted in the establishment of advanced manufacturing facilities, including the world’s most advanced charging production plant in Guanajuato, Mexico.
Through Industry 4.0 it has improved its production processes and achieved exceptional quality control, as evidenced by its ability to produce tens of thousands of charging devices without a failure. With new customers set to launch products in the coming months, Webasto Charging remains committed to upholding its high standards of quality while continuing to innovate and develop new products.
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The Next Generation Coolant Heater is visually quite different from Webasto’s previous high-voltage heaters. It is smaller, lighter and more sustainable, according to the Munich-based company. In addition, it is based on one platform, which means it can be flexibly adapted to different customer requirements. The heating technology is also different, according to Webasto: “It is based on innovative heating technology that is integrated into an installation-space-optimized heat exchanger and is suitable for both 400- and 800-volt vehicle architectures.” According to the manufacturer, the heating capacity is scalable from three to six to nine kilowatts. Following the logic of the product names, the new high-voltage heater will therefore be called Webasto HVH 90 Next Generation Coolant Heater (for up to 9 kW, the HVH 100 delivers 10 kW).
According to Webasto, the first major European order for the Next Generation Coolant Heater has already been won. However, the Munich-based supplier is not disclosing details; it only emphasises that the new product “facilitates a flexible interface with the customer’s vehicle architecture, irrespective of voltage and heat output.” According to the Munich-based company, the first vehicles with the new HVH will be on the road in two years.
“The concept is our answer to wide-ranging customer requirements and allows us to scale along demand,” expresses Marcel Bartling, Chief Technology Officer of Webasto SE. “The new platform gives our customers a flexible interface. By taking a modular approach we are able to achieve a high level of production automation, offering excellent flexibility in terms of the higher volumes we can manufacture.”
Webasto describes the improvements in weight and material use as follows: “The aluminum content of the Next Generation Coolant Heater is reduced by almost 50 per cent compared to the actual 10 kilowatt variant, ensuring a weight reduction of 30 percent,” says Bartling. “Webasto is taking an important step towards sustainability with this new concept.”
The heating systems for hybrid and electric vehicles temper both the vehicle cabin and the batteries. With the HVH 100, Webasto has already been producing an 800-volt coolant heater with 10 kW heating capacity in series since 2019. Webasto is now presenting two offshoots at the IAA Mobility: the HVH 100 Compact, which also has a heating capacity of 10 kW, but is smaller in size and weight. This should be available from 2024. And the HVH 120 with 12 kW heating power especially for commercial vehicles. This high-voltage heater is also to be added to the Webasto portfolio from 2024.