Intelligent power management company Eaton has announced a significant partnership with Munich Electrification to develop and market a new battery configuration switch (BCS), a cutting-edge solution designed for 400-volt/800-volt dual string battery packs in electric vehicles (EVs). This innovative bi-stable device allows for efficient parallel/series reconfiguration, enabling 800-volt vehicles to charge effectively using 400-volt chargers, thus providing greater flexibility for consumers.
The announcement highlights Eaton’s commitment to advancing electrified mobility solutions. Mark Schneider, president of Eaton’s eMobility division, emphasised the potential of the BCS technology, stating, “There are a lot of 800-volt vehicles in the market, but many charging stations can only supply 400-volt power. BCS provides charging flexibility to consumers who want access to an expanded network of DC chargers.”
Eaton’s BCS has been engineered for use in a variety of applications, including automotive, light commercial vehicles, and utility task vehicles (UTVs). One of its standout features is the reduction of up to 12 components in a typical battery disconnect unit, which simplifies the overall system design and facilitates easier packaging and assembly. Additionally, the BCS minimises contact resistance, improving the efficiency and performance of the system by decreasing the number of contact points needed compared to traditional contactors.
Safety is a paramount concern for electric vehicles, and the BCS addresses this with a mechanical interlock designed to prevent short circuits in the event of a crash, software failures, or contactor malfunctions. The device can maintain stable operational conditions even if the electronic control unit loses power. Its bi-stable nature not only enhances operational efficiency by eliminating the hold current found in conventional contactors but also ensures resilience against low voltage faults, providing safety across a wide range of potential failure modes.
Uwe Wiedeman, managing director of Munich Electrification, expressed enthusiasm about the collaboration, stating, “We are thrilled to collaborate with Eaton in launching this groundbreaking new technology developed by our outstanding R&D team. Munich Electrification’s legacy of innovation in the EV battery industry, combined with Eaton’s expertise in electrical switching and automotive manufacturing, is helping us to solve our customers’ biggest challenges together.”
As the demand for electric vehicles continues to rise, Eaton’s BCS technology represents a vital step towards enhancing charging infrastructure and battery efficiency. By addressing the current limitations of charging systems, this partnership aims to pave the way for broader adoption of electric vehicles, ultimately contributing to a more sustainable future.
Eaton is an intelligent power management company focused on environmental protection and improving the quality of life globally. With products spanning data centres, utilities, industrial sectors, and more, Eaton is dedicated to sustainability and helping customers manage power effectively. Founded in 1911 and publicly listed for over a century, the company reported revenues of $23.2 billion in 2023 and serves customers across more than 160 countries. For further information, visit www.eaton.com.