Vehicle electrification is progressing globally. More electric vehicles (EVs) are being registered (16.5m in 2021) and the number of publicly accessible charging stations are steadily increasing (500k in 2021). A large portion of this development and infrastructure concerns passenger vehicles, but EV commercial fleets are a key driver in climate-friendly mobility.
Road freight vehicles (trucks, lorries, vans) accounted for less than 2% of vehicles in Europe, but made up 23% of road transport CO2 emissions in 2019. But due to their high weight demands and significant battery capacity, finding efficient charging solutions for large commercial fleet EVs has been a challenge.
Megawatt Charging Systems are a driving force in the electrification of large commercial vehicles by providing unmatched speeds and charging capabilities. But what exactly is a MCS, and how can it revolutionise commercial EV charging?
The Megawatt Charging System (MCS) is a product of the lack of sufficient charging solutions for large EVs like trucks and lorries. Currently, DC chargers are the fastest charging solution available being rated at highs of 350kW. Where this is impressive for the likes of passenger cars, there is still potential for maximising the charging time for larger vehicles with greater energy capacity.
CharIN, the leading association in the global standard of Combined Charging Systems (CSS), created a High Power Charging for Commercial Vehicle Task Force (HPCCV) in 2018 to address the lack of charging standards for large commercial EVs. They discovered that in order to charge a truck carrying 200-600kWh batteries in 20-30 minutes, they would require power levels of over 1 MW.
The task force consists of a wide range of EV and automotive industry leaders, such as Tesla, Ford, Porsche, as well as standardisation bodies like SAE. Together, they submitted and approved various designs over the next six years, resulting in the first complete specification document being published in 2022.
CharIN’s recommendations and requirements for the MCS states a maximum current of 3000 A at 1.25 kV, resulting in a peak charging potential of 3.75 MW. This is more than enough for a large truck to reach full charge in under 30 minutes, maximising driving range gained per minute spent charging and effectively eliminating idle charging time outside of designated breaks.
That said, there is still further testing required on voltage range, current capability, associated thermal performance and other components before its application is possible. In 2022, a prototype was showcased to the public for the first time that charged at a maximum of 1.2 MW; less than the potential peak of 3.75, but still capable of the full commercial optimisation benefits for businesses.
MCS is designed as a holistic system that can be used across all large commercial vehicles on globally aligned requirements. This means that future class 6, 7 & 8 EV commercial vehicles will be designed with MCS connectivity in mind. These vehicles can range from buses and trucks to small/medium sized aircrafts.
With sufficient MCS infrastructure along commercial routes, businesses can fully charge their large EV fleets during the designated rest periods that are required by law. Not only does this optimise operational efficiency, but can completely remove the need for dedicated idle charging time; which is a significant incentive for businesses to switch from combustion to electric fleets.
MCS presents a world of opportunities for commercial EV charging, as well as EV infrastructure in general. The impressive speeds and global standardisation of charging both present an efficient and optimised future for road freight vehicles, public transport and more. However, its global application is far from close, requiring further testing and compliance/standardisation checks to be realised.
With Dalroad, you can not only be aware when MCS becomes the standard, but have access to all the necessary information to future-proof your designs. We have a full team of experienced engineers to provide you with unbiased advice. Contact a member of our team today to discover a world of connectivity components and systems for your current project.
