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Battery configuration switch

The growth of the electrical vehicle (EV) market has brought an increasing demand for improved performance and faster charging. As OEMs adapt to these needs by transitioning from 400V to 800V batteries, they face a new challenge. Much of the public EV charging infrastructure is built to support 400V EVs. Without additional, sometimes costly equipment, 800V EVs are not able to use these chargers.

Eaton’s Battery configuration switch (BCS) solves this challenge in one innovative device that is integrated into the battery pack.  Designed for passenger and light duty commercial vehicle applications, the BCS is a bi-stable device that safely and efficiently transitions pack voltage between 400 and 800 volts, enabling EVs to charge at a different voltage than vehicle operation.  

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Reduced complexity ​
Enables reduction of up to 12 components in a Battery Disconnect Unit (BDU) 
Reliable safety
Rotational motion creates a mechanical interlock that prevents an accidental short circuit condition
Maximize performance
Allows the battery to draw maximum current even at a 400V DC fast charger
BCS Configuration - 1

核心功能

  • Enables electric vehicles to charge at a different voltage than vehicle operation with maximum performance on all DC charging infrastructures.
  • Designed for automotive, light commercial vehicle and UTV applications 
  • 500A continuous current without cooling possible
  • Switch series to parallel configurations in <500 ms
  • Alternately replaces three single pole contactors for voltage reconfiguration
  • Stable positions in loss of KL30C cases
  • No power consumed in coil during operation allowing for increased efficiency  

 

Product Benefits

  • Reduced complexity – Enables the reduction of up to 12 components in a Battery disconnect unit (BDU), simplifying the system and streamlining packaging and assembly
  • Reliable safety – Rotational motion creates a mechanical interlock that prevents an accidental short circuit condition
  • Optimized charging – Can eliminate a buck/boost converter on 800V EVs, allowing the battery to draw maximum current even at a 400V DCFC charger
  • Enhanced efficiency – Maintains a stable position with no low voltage hold current, eliminating parasitic loss, improving vehicle efficiency and ensuring functionality and safety even if low voltage power is lost
  • Quicker startup time – Due to its bi-stable nature, the BCS desired configuration can be pre-selected at startup or left from last shutdown. The BCS can also offer disconnect positions for maximum safety during shutdown

规格
  2-state VRS  3-state VRS  Notes
Configuration
Parallel (400V)  X X  
Series (800V) X X  
Disconnect   X  
Contact Resistance 800V <100 µOhm  <100 µOhm   
Contact Resistance 400V  <100 µOhm per string  <100 µOhm per string   
Current Carrying  500A without external cooling  500A without external cooling  Higher current can be achieved with liquid cooling 
Make and Break Current  Max 50A  Max 50A  400V strings must be balanced to limit inrush current 
Control for reconfiguration   7W for 0.5s  CTRL Signal ON (12V) 

The reconfiguration is 

bi-stable. It requires a pulse to change direction 
Dimensions/Weight 

126mm x 62mm x 110mm  

360g 

126mm x 62mm x 110mm  

390g 

  
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