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Megawatt Charging System

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MCS
Speculative v3.2 MCS connector; there are two primary power (DC) pins, four communications/detection (C) pins, and one protective earth (PE) pin.
Type Electric vehicle charging
Production history
Designer MCS (former HPCCV) working group, CharIN
Designed 2020‒2022
Produced 2023‒
General specifications
Pins 5–7
Connector MCS
Electrical
Signal DC
Earth Dedicated pin
Max. voltage 1,250 V
Max. current 3,000 A
Data
Data signal ISO 15118-20

The Megawatt Charging System (MCS) is a charging connector under development for large battery electric vehicles. The connector will be rated for charging at a maximum rate of 3.75 megawatts (3,000 amps at 1,250 volts) direct current (DC). The MCS connector is expected[by whom?] to be the worldwide standard charging connector for large and medium commercial vehicles be it on land, water or in the air.[not verified in body]

History

A Charging Interface Initiative e.V. (CharIN) task force was formed in March 2018, with the purpose to "define a new commercial vehicle high power charging standard to maximize customer flexibility."[1] CharIN had previously developed the Combined Charging System (CCS) specification. From early 2018 until late 2019, the abbreviation HPCCV (High Power Charging for Commercial Vehicles) was used, following the name of the CharIN consortium taskforce. The purpose statement was later revised to "work out requirements for a new commercial vehicle high power charging solution to maximize customer flexibility when using fully electric commercial vehicles. The scope of the technical recommendation is to be limited to the connector, and any related requirements for the EVSE, the vehicle, communication, and related hardware."[2]

The HPCCV held a meeting in September 2018 to gain consensus on proposed requirements, and the CharIN Board of Management approved the consensus requirements on November 28, 2018.[1] Five companies submitted candidate designs to meet the requirements: Tesla, Electrify America, ABB, paXos, and Stäubli.[3] HPCCV selected a charging plug and socket design in May 2019, which was endorsed by CharIN leadership in September 2019.[1] The version 1.0 HPCCV connector had a triangular shape and round power pins, but the design required further development as it was not finger-proof.[4]: 3 

Approximate drawing of previous version 2 draft outlet; DC± would have been carried via two "tuning fork" contacts

A test of seven vehicle inlets and eleven connectors was held at the National Renewable Energy Laboratory (NREL) on September 23–24, 2020. The prototype hardware represented designs from seven different manufacturers, and six additional manufacturers participated virtually. Criteria evaluated included fit/compatibility, ergonomics, and thermal performance.[5][6] Evaluations at maximum current (3000 A) were conducted with cooling of both the inlet and the connector; for connector cooling only, current was limited to 1000 A, and without cooling, current was limited to 350 A.[7] Versions 2.0 through 2.4 of the MCS connector used "hairpin" shaped contacts, but it was later changed to version 3.0 through 3.2, which returned to the triangular shape with larger pins and longer protective sheaths to prevent accidental contact.[4]: 3 

The task force had anticipated that a requirements and specification document would be published by the end of 2021.[2] In August 2021, prototype connectors were tested at up to 3.75 megawatts.[8] MCS connector version 3.2 was adopted in December 2021.[4]: 3 

Specific implementations

Lilium announced in October 2021 that forthcoming VTOL Lilium Jets with their 900 kWh battery would be fitted with MCS for charging.[9] Charging stations with MCS connectors will be delivered by ABB in 2024.[10]

The national project „Hochleistungsladen im Lkw-Fernverkehr“, commonly referred to as the HoLa project (from German Hochleistungs-Ladepark, literally high capacity charging park for the charging sites),[11] will build four new truck charging stations along the Autobahn A2 from Berlin to Duisburg. Each station will be equipped initially with two 600 kW stations starting in June 2022, and will be upgraded to 1 Megawatt using MCS in fall 2023. The chargers will be built by Heliox.[12]

The German Association of the Automotive Industry (VDA) published the "Masterplan Ladeinfrastruktur 2.0" in February 2022 in which they proposed to extend the Deutschlandnetz state-funded charging network into a "Deutschlandnetz für Lkw" (national fast-charging network for trucks). Whereas the current plan requires 200 kW per charging point using CCS, the next phase will require 700 kW per charging point using MCS.[13]

Design requirements

Key requirements include:[2]

  • Single conductive plug
  • Maximum of 1250 V DC and 3000 A
  • PLC + ISO/IEC 15118
  • Touch Safe (UL2251)
  • On-handle software-interpreted override switch
  • Adherence to OSHA / ADA (or local equivalent) standards
  • FCC Class A EMI (or local equivalent)
  • Located on driver's side of the vehicle, hip height
  • Capable of being automated
  • UL / NRTL certified
  • Cyber-Secure
  • V2X (bi-directional)

MCS is intended for Class 6, 7, and 8 commercial vehicles, initially with a primarily focus on large trucks and busses, but there’s also there’s also demand for MCS in the Aeronautics industry (e-VTOL, e-Planes, etc…) and the Marine Industry (Tug-boats, e-Ferries, River Cargo vessels, etc…). The vehicle inlet should be placed on the driver's side of the vehicle (left side in North America), between the front and rear axles.[14]: 17 

The ISO15118-20 Communication Protocols will allow bi-directional energy flow for vehicle-to-grid (V2G), Smart Charging, Encrypted Communication, Plug ‘n Charge, Automated Charging. SAE International began developing the MCS standards into the J3271 set of requirements in December 2021.[15] In parallel, the IEC began developing standard 63379 in Spring 2021.[16]

A CCS Combo 1/Combo 2/SAE J3068 or ChaoJi inlet may also be fitted to the vehicle for compatibility and AC charging. Black & Veatch have designed prototype layout requirements for vehicle charging lanes.[17]

See also

References

  1. ^ a b c "CharIN HPCCV Task Force: High Power Plug Update". CharIN. April 2020. Retrieved 26 August 2021.
  2. ^ a b c "Megawatt Charging System (MCS)". CharIN e.V. Retrieved 26 August 2021.
  3. ^ Kocher, Rustam (2019-06-11). "Standardization Task Force update" (Document). {{cite document}}: Cite document requires |publisher= (help); Unknown parameter |access-date= ignored (help); Unknown parameter |series= ignored (help); Unknown parameter |url= ignored (help)
  4. ^ a b c Bohn, Theodore (April 12, 2022). "SAE J3271 Megawatt Charging System standard; part of MW+ multiport electric vehicle charging for everything that 'rolls, flies or floats'". EPRI Bus & Truck. Retrieved 8 June 2022.
  5. ^ "The CharIN path to Megawatt Charging (MCS): Successful connector test event at NREL" (Press release). 2020-10-13. Retrieved 2021-01-10. On September 23-24, 2020 … Fit and ergonomics evaluation of the MCS connector and inlet … At the facilities of National Renewable Energy Laboratory (NREL)
  6. ^ "NREL-Hosted Event Supports Industry Development of Megawatt Charging System Connectors" (Press release). NREL. 2020-10-12. Retrieved 2021-01-10. Megawatt Charging System (MCS), a new charging standard for medium- and heavy-duty electric vehicles … enabled seven vehicle inlets and 11 charger connectors to test their designs together. … high-current nature of this system presents unique challenges to minimize cable length to improve efficiency and reduce thermal cooling … test matrix covering all connector and inlet combinations. … CharIN group has identified a list of priority requirements for a new high-power bidirectional charging system, including compatibility with up to 1,500 volts and 3,000 amps.
  7. ^ Meintz, Andrew (June 24, 2021). "Charging INfrastructure Technologies: Development of a Multiport, >1 MW Charging System for Medium- and Heavy-Duty Electric Vehicles" (PDF). National Renewable Energy Laboratory. Retrieved 26 August 2021.
  8. ^ Industry Experts, Researchers Put Charging Systems for Electric Trucks to the Test. News (Report). National Renewable Energy Laboratory. 2021-08-03. Retrieved 2021-10-11.
  9. ^ "ABB and Lilium team to revolutionize charging infrastructure for regional air travel" (Press release). ABB. 2021-10-13.
  10. ^ "Lilium Partners with ABB for Charging Infrastructure". Transport UP. 2022-02-22.
  11. ^ "HoLa – High performance charging for long-haul trucking". Hochleistungsladen Lkw-Fernverkehr. Retrieved 8 June 2022.
  12. ^ "Heliox: From coarse to fine adjustment of the megawatt charge". 2021-10-16.
  13. ^ "Aufbau E-Ladenetz für Nutzfahrzeuge fokussieren – 5 Mrd. Booster-Förderung bis 2025" (Press release). VDA - Verband der deutschen Automobilindustrie. 2022-03-11.
  14. ^ Truemner, Russell (2019-02-18). "Task Force Aggregated Requirements" (Document). {{cite document}}: Cite document requires |publisher= (help); Unknown parameter |access-date= ignored (help); Unknown parameter |archive-date= ignored (help); Unknown parameter |archive-url= ignored (help); Unknown parameter |series= ignored (help); Unknown parameter |url-status= ignored (help); Unknown parameter |url= ignored (help)
  15. ^ "Megawatt Charging System for Electric Vehicles: J3271". SAE International. December 15, 2021. Retrieved 3 May 2022.
  16. ^ Bernd Horrmeyer (December 2, 2021). "Megawatt Charging System: Standardization supports global electrification of heavy-duty traffic" (Interview). Interviewed by Gürkan Balcioglu. DKE Technology.
  17. ^ Pollom, Russell E. (May 5, 2021). "Black & Veatch Layouts for MCS Working Group" (PDF). Charging Interface Inititative (CharIN) Megawatt Charging System Task Force. Retrieved 26 August 2021.
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