Heavy-Duty Electric Truck Charging

The electrification of trucks is an inevitable trend in the global transportation sector under the goal of carbon neutrality. Especially, the electrification of heavy-duty vehicles is a key building block for the transport transition. In long-haul transport alone, 100,000 electric trucks weighing 40 tons can save up to 10 million tons of greenhouse gas emissions annually. Electric trucks, characterized by their zero-emission features, are projected to reach 600,000 units in number, at least 50% of new trucks in the European Union (EU) by 2030 based on the estimation from Daimler Truck, Traton Group and Volvo.

One of the obstacles in front of the development of zero-emission heavy transport is related to the characteristics of the batteries and charging. Unlike passenger EVs, electric trucks often have far larger battery packs and usable battery capacities in order to empower a similar range to conventional fuel vehicles. It’s said that the battery capacities of new-generation heavy-duty vehicles could be as large as 600kWh to 1000kWh. However, the highest power that current CCS (Combined Charging System) connectors can deliver is limited within 375kW, leading to long charging times and influenced operating revenue. So, it is essential to introduce the ground-breaking ultra HPC (High Power Charging) solution to charge heavy shippers within a reasonable time—MCS.

MCS (Megawatt Charging System), adopting a specialized charging connector, provides a high-speed charging solution for commercial electric vehicles with large batteries. According to CharIN, the MCS could convey maximum 3000A and 1250V direct current (DC) by a single conductive plug and achieve a rated power of 3.75MW, which is nearly ten times of current CCS Combo connectors. Advanced by CharIN, MCS is expected to become a standard charging solution for large and medium commercial vehicles. When electrifying long-distance heavy-duty transport, MCS solution can extend the range by 300 to 400 kilometers during mandatory rest periods required by the European Regulation, which stipulates a 45-minute stop every four and a half hours of driving, since it boasts ultra-fast charging from 10% to 80% in just 30 minutes.

Initially with a primary focus on large truck and bus charging, MCS demonstrates significant technical advantages in heavy-duty electric charging. Firstly, its high-power charging capability greatly reduces charging time, improving the operational efficiency of electric heavy-duty trucks. Secondly, its efficient energy transfer capability significantly enhances the charging efficiency of electric trucks, optimizing energy utilization and promoting sustainable development in heavy-duty truck transport.

To drive zero-emission transportation of electric trucks and buses, Infypower offers customizable liquid-cooled MCS solution from 600kW to 1.2MW. In particular, our overhead HPC solution tailored for eBus fast charging at depot, allows CPOs to integrate charging facilities seamlessly with existing parking infrastructure. In addition, it also ensures electric buses to get charged smoothly and efficiently while achieving optimal power utilization at all times. This is because that Infypower HPC system is designed to distribute power dynamically and flexibly to all charging ports. Dynamic power sharing feature not only optimizes power utilization but also helps avoid oversized charging infrastructure.

More importantly, the switching from fan-cooled charger modules to liquid-cooled charger modules brings significant benefits in helping CPOs cope with noise pollution, charging efficiency, reliability and maintenance problems. The HPC system can achieve ultra low noise level of 50dB with adjustable speed AC fans at 45℃ ambient temperature. Featuring SiC Mosfet and innovative topology, Infypower liquid-cooled charger module (LRG1K0100G ) boasts over 96% efficiency from 300Vdc to 1000Vdc and from 40% load to 80% load. At the system level, its load ratio can be controlled above 40%, ensuring the highest possible efficiency of charger modules. Employing liquid cooling design prevents air exchange between module interior and exterior so that the power cabinet of our HPC solution can be rated IP65, guaranteeing high reliability in harsh outdoor environment charging. Also, the liquid cooled HPC solution eliminates the need for dust filters, avoiding periodic replacement and saving labor costs associated with routine maintenance.

Infypower liquid-cooled MCS solution consists of separate power cube and charging dispensers. The base configuration supports up to 10 charging terminals. Overhead dispenser option facilitate eBus charging at bus depots with limited space. To overcome grid constraints and limitations in some areas, we can also integrate liquid-cooled MCS solution with current liquid-cooled energy storage solution, making a seamless combination of PV, ESS, EV charging and V2G functions. Now it's possible to run MCS even with small or limited grid power.

Besides heavy commercial EV charging, MCS can also apply to electric vessels and aircrafts. Together, we aim to drive sustainable transport and eMobility worldwide.

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