58 socket terminals and terminated at the other end with electrical connection lugs, was bolted to an NREL-provided bus bar and instrumented with up to 14 thermocouples. Transducers were also provided to enable data collection from optional participant-provided Pt1000 resistance temperature detectors. Before being placed under test, the connector would be mated to a participant-provided inlet with shorted terminals or electrical connection lugs that would then be bolted to an NREL-provided bus bar, with a cable approximately 0.75 m long. The inlet was instrumented with up to 13 thermocouples to test the thermal compatibility. For future MCS connector designs to be evaluated more effectively by industry, a reference device has been developed by the IEC PT63379 working group to serve as a standard inlet that can provide a baseline minimally acceptable thermal performance. Reference device evaluations consisted of two types of characterisations. During the first characterisation, connectors were run at either 1500 or 3000 A, depending on their current rating, until the devices reached steady state, with cooling levels similar to those used in the interoperability evaluations. The second type of characterisation, performed with only certain connectors, consisted of running the device at rated current, then adjusting the cooling level until the reference inlet pin temperatures reached a target level of 100 C (at 40 C ambient) or 85 C (at 25 C ambient). Each evaluation was performed at 40 C, and repeated at 25 C, to help evaluate the necessity and performance implications of the 40 C ambient temperature test requirement. NEFTON project To cover long distances daily, trucks require up to 1000 kWh of energy. Batteries of this size represent a considerable financial investment as well as a considerable weight. However, megawatt charging with the new MCS standard can reduce the required size to 450 kWh, significantly increasing the cost-effectiveness and sustainability of battery electric trucks. This reduction in battery size is the core idea of the NEFTON project in Germany, which has developed a prototype vehicle and a prototype charging station that enable charging with up to 1000 kW in 30 minutes, well within the legally prescribed breaks for drivers. On the vehicle side, various components interact to support megawatt charging. A modular battery concept is necessary to meet user requirements because larger battery capacities reduce the charging rate of the cells and thus enable higher charging power. Despite the rise in temperature in the battery system due to charging losses, thermal management enables largely constant charging over most of the charging process. Optimised cooling and an efficient charging system are crucial for reducing operating costs and maximising vehicle availability while ensuring flexibility and user orientation. The charging infrastructure in the NEFTON project was implemented in a modular way to enable fast and flexible installation. The inner intelligence of the infrastructure lies in the interconnection of power electronics modules via a switching matrix, and the combination of modular bidirectional power electronics with highly efficient unidirectional Deep insight | Megawatt charging May/June 2025 | E-Mobility Engineering An MCS connector and inlet set for launch later in 2025 (Image courtesy of Stäubli) Thermal test setup for an MCS connector (Image courtesy of NREL)
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