Eaton has partnered with Munich Electrification to develop and market its battery configuration switch (BCS), an advanced solution for 400-volt/800-volt dual string battery packs in electrified vehicles. This integrated, bi-stable device for parallel/series reconfiguration allows 800-volt vehicles to effectively charge via a 400-volt charger, while also offering numerous benefits compared to traditional solutions.
Designed for automotive, light commercial and UTV applications, Eaton’s BCS enables the reduction of up to 12 components in a battery disconnect unit, simplifying the system and streamlining packaging and assembly. Furthermore, the BCS minimizes contact resistance, enhancing overall system efficiency and performance by reducing the number of contact points required by conventional contactors.
Ensuring higher EV safety standards, the BCS has a mechanical interlock that prevents pack short circuits due to crashes, software bugs, or contactor malfunctions. The BCS can also maintain stable conditions when the electronic control unit loses power. Its bi-stable nature enhances efficiency during normal operations by eliminating the hold current of a traditional contactor, and also provides resilience against low voltage faults by maintaining a safe condition for a wide range of potential failure modes.
“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.”
Mark Schneider, president, Eaton’s eMobility
