In the rapidly evolving world of EVs, the need for efficient and flexible charging solutions is paramount.
Eaton, a leader in intelligent power management, has collaborated with Munich Electrification (ME) to introduce a groundbreaking innovation: the Battery Configuration Switch (BCS). This advanced solution is designed to divide a vehicle’s battery pack into two virtual sub packs, each at 400-volts. The BCS then allows the vehicle to operate or charge with these sub packs in parallel for an operating voltage of 400-volt, or in series for an operating voltage of 800-volt. This optimizes charging for EVs by allowing the vehicle to charge natively at either 400 or 800-volt.
Many public DC fast charging stations can only supply 400-volt power. Eaton’s BCS allows 800-volt vehicles to charge effectively using 400-volt chargers by changing the vehicle’s effective pack voltage. This capability significantly enhances charging flexibility by expanding the network of accessible DC chargers for EV owners.
Eaton’s BCS is engineered to reduce cost and complexity by eliminating up to 12 components in the battery disconnect unit. This simplification not only enhances the system’s packaging and assembly but also minimizes contact resistance, leading to improved overall system efficiency and performance.
Safety is a critical consideration in EV technology, and Eaton’s BCS excels in this area. The BSC features a mechanical interlock that prevents short circuits caused by crashes, software bugs, or contactor malfunctions. Additionally, the BCS maintains stable conditions even when the electronic control unit loses power, ensuring higher safety standards for EVs.
The bi-stable nature of Eaton’s BCS eliminates the hold current required by traditional contactors, further enhancing efficiency during normal operations. This design also provides resilience against low voltage faults, maintaining a safe condition across a wide range of potential failure modes.
The development the BCS is a testament to the power of collaboration. Munich Electrification’s expertise in cutting-edge battery management systems, combined with Eaton’s extensive background in electrical switching and automotive manufacturing, has resulted in a solution that addresses some of the biggest challenges faced by the EV industry today.
The BCS is designed for a variety of applications, including passenger and light commercial vehicles as well as utility terrain vehicles (UTVs). This technology reflects Eaton’s commitment to developing sustainable and innovative solutions for the evolving electric vehicle market.
Eaton’s Battery Configuration Switch is a groundbreaking solution that addresses the challenges faced by the evolving electric vehicle market. By enabling efficient voltage reconfiguration, the BCS enhances charging efficiency, reduces system complexity, and ensures reliable safety. As the EV industry continues to grow, innovations like the BCS will play a crucial role in driving the adoption of electric vehicles and improving the overall user experience.
