The partnership-based demonstration project aims to make e-trucks suitable for long journeys and relieve the strain on grids. The technical basis is a new charging standard for heavy commercial vehicles.
One of the world's first megawatt charging stations is currently being built at Designwerk Technologies AG. The charging station in container format is set to charge electric trucks for the first time in spring 2023. It will be up to six times faster than conventional high-performance charging stations with 350 kW output. Integrated battery buffers are designed to avoid peak loads. The aim is also for the charging stations to be grid-friendly. The scientific support for these technical developments is being provided by the Swiss Federal Office of Energy (SFOE) and renowned industrial partners. On the research side, the Bern University of Applied Sciences (BFH) and the University of Applied Sciences of Eastern Switzerland (OST) are involved in the project.
Charging infrastructure for commercial vehicles is essential
Heavy goods vehicles are of key importance for the energy transition and achieving climate targets. Around 6.6 million trucks are in use on Europe's roads. They transport 76.7% of all freight on land. Consequently, it is important to increase the proportion of low-emission or emission-free means of transport here too. "Long-distance trucks, ships and aircraft in particular require a new type of charging infrastructure. It differs from the infrastructure for electric cars and makes it possible to charge heavy commercial vehicles in a short time. This helps to ensure that zero-emission freight transport reaches all areas of application," explains Vivien Dettwiler, member of the Designwerk management team. To ensure that the system meets with the necessary acceptance, it is based on the new charging standard Megawatt Charging System, or MCS for short. This was launched internationally in June of this year.
Security of supply as part of the project
The realization that powerful charging stations place demands on grids is an integral part of the project's starting point. The demonstration operation is therefore intended to show ways in which a high-performance charging network and security of supply can go hand in hand. "We install Second Life e-truck batteries in our charging containers as a buffer to prevent peak loads. This not only eliminates the need to expand the grid: the storage system should even be able to feed renewable electricity back into the grid," says Dettwiler. Similar to bidirectional charging, electromobility can be used as part of supply solutions. Demonstration systems at Galliker Transport AG, Käppeli Logistik and Murg Flums Energie will prove that this works.
Key technical data Mega Charger demonstration system
Prototype construction site: Winterthur, Switzerland
Demonstration project: Megawatt battery charging system for heavy commercial vehicles
Product name: Stationary Battery Backed Mega Charger
Dimensions L×W×H: 8500×2550×3000mm
Weight: 25 t
AC input data: 88-400 kW, TN 3x125-580 A, 400 VAC +-10%, 50 Hz
AC plug type: CEE 125 and fixed connection, 3P+N+PE
Battery buffer: 1,800 kWh
Technology Battery storage: NMC, second life use or new
DC output data: max. 3,000 A, 500-900 V, max. 2,100 kW
DC Plug type: Liquid-cooled, CCS type 2, MCS
Efficiency: Mains > battery > vehicle > approx. 0.9
Operation: Status display, buttons
Connectivity: OCPP 1.6j, Modbus
Thermal management: Water / air: stepless, temperature-dependent
Transport: Container Transportable according to UN38.3
