Summary
- Transition to electric vehicles faces challenges with availability of high-speed DCFC infrastructure
- OEMs considering move to 800V architecture from 400V platforms for EVs
- Eaton’s Battery Configuration Switch addresses the challenge by transitioning pack voltage between 400 and 800 volts
- BCS eliminates need for additional equipment for interfacing with high-power DCFC infrastructure
- BCS enhances safety, efficiency, and charging performance for EVs, showcasing Eaton’s commitment to innovation
Article
The transition to electric vehicles is often hindered by the lack of high-speed Direct Current Fast Charging (DCFC) infrastructure, especially as many Original Equipment Manufacturers (OEMs) are considering moving towards 800V architecture instead of the widely available 400V platforms. This shift can improve vehicle efficiency and charging speed but poses a challenge as much of the installed high-power DCFC infrastructure in the US and Europe is limited to 400 Volts. This limitation requires additional, costly equipment for an 800V vehicle to interface properly. Eaton’s Battery Configuration Switch (BCS) offers a solution to this challenge by efficiently transitioning pack voltage between 400 and 800 volts to maximize charging speed on existing infrastructure.
Designed for passenger and light-duty commercial vehicles, the BCS is a bi-stable device that connects two 400-volt sub-packs in series to achieve 800 volts in its normal operating mode. This configuration allows the EV to charge efficiently on 400 Volt DC fast chargers. The BCS eliminates the need for multiple contactors, busbars, and harnesses, reducing cost and complexity while enhancing charging performance. Additionally, the BCS enhances safety by using an internal rotary switch to prevent short circuits and maintain stability without low voltage hold current, ensuring vehicle efficiency and functionality even in the case of power loss.
Eaton’s BCS represents a significant advancement in EV technology, offering a robust, efficient, and cost-effective solution for battery pack voltage reconfiguration. This innovation underscores Eaton’s commitment to excellence in power management. Those interested in learning more about the BCS and its benefits can join the upcoming webinar at the Virtual Conference on EV Engineering, presented by Eaton. The webinar will cover the features and advantages of the BCS, highlighting its role in overcoming the challenges associated with high-power DCFC infrastructure and advancing the adoption of electric vehicles.
In addition to the BCS presentation, the Virtual Conference on EV Engineering will include other sessions covering various topics within the realm of electric vehicles. For example, there will be a session on High-Voltage Protection in DC Fast Charging, presented by TTI and Sensata. This session will delve into the importance of robust protection mechanisms in HVDC systems to ensure operational safety and reliability. Critical components such as high-voltage contactors, isolation monitoring modules, and fast disconnect devices will be discussed in terms of their design, operational principles, and applications in EVs and charging systems.
Attendees of the Virtual Conference on EV Engineering will have the opportunity to explore a wide range of topics related to the EV engineering supply chain and ecosystem. The conference content will cover areas such as motor and power electronics design and manufacturing, cell development, battery systems, testing, powertrains, thermal management, circuit protection, wire and cable, EMI/EMC, and more. The event will be broadcast live on March 10-13, 2025, providing valuable insights and knowledge-sharing opportunities for professionals and enthusiasts in the electric vehicle industry. Reserve your spot for the conference to access cutting-edge information and network with industry experts.
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