A few years ago, the implementation of the Megawatt Charging System (MCS) in the electromobility sector seemed a remote possibility.
However, the determination, research, and investment from various sector stakeholders have brought this technology closer to reality, to the point where multiple tests have already been conducted on electric trucks.
Nevertheless, this innovation comes with initial challenges, one of the main ones being communication between the charging station and the vehicle during the MCS process.
In this context, the Research and Transfer Centre e.V. (FTZ) at the University of Zwickau, Western Saxony, Germany, is seeking a solution.
“The aim of the research project is to design the communication to be resistant to interference,” explains the FTZ project director and chairman of the board, Prof. Dr. Matthias Richter, to Mobility Portal Europe.
Electromagnetic interference can cause failures in the “refuelling” process, which could have serious consequences for both vehicle safety and infrastructure efficiency.
He adds: “As well as anchoring it in international standards for the emission of electromagnetic interference from charging and for the design of communication systems.”
Ultimately, they hope to standardise these results internationally.
The MCS enables electric cars to receive charges of up to 1,250 volts and 3,000 amps, far surpassing the capabilities of conventional chargers.
This promises to reduce downtime and make vehicles a more viable option for freight transport.
The FTZ has been working for over 30 years on issues related to electromagnetic compatibility (EMC) in motor vehicles, and is now applying its expertise to address the specific problems of this technology.
To achieve this, the team has focused its efforts on optimising the communication channel at both ends of the charging system.
This includes improving the design of data transmission channels, introducing shielding to protect against electromagnetic interference, and adjusting international standards to meet the new needs of the MCS.
These measures aim to ensure that the systems are robust enough to handle the high voltages and currents involved in MCS.
Richter explains: “This is essential to meet the increasing demands of the new high-performance charging technology.”
In this framework, researchers are working on adapting the limit values for high-voltage cables specifically for MCS in the international standard IEC 61851-21-2.
This adjustment ensures that cables and other “refuelling” infrastructure components can withstand extreme conditions without compromising safety or efficiency.
Another important aspect being addressed is the need to adjust the Power Line Communication (PLC) system to align with existing international regulations, such as ISO 15118 and DIN SPEC 70121.
These changes are necessary to ensure that communication between the station and the vehicle is consistent and efficient, avoiding problems that could arise from discrepancies between guidelines.
To this end, the team is collaborating with companies in the German automotive industry, particularly with a manufacturer as a key partner.
Who will benefit from this approach?
“Every user of electric vehicle charging infrastructure supports these solutions, as charging processes are not interrupted by failures,” says Richter.
The ability to develop effective solutions for communication problems in MCS could set a precedent for other future developments in the field of electromobility.
About the Research and Transfer Centre e.V. (FTZ)
In 2023, FTZ e.V. generated approximately 2.6 million euros in research and development contracts with industry and federal and state governments.
The association, founded on 8 November 1994, employs over 60 people in 11 research areas and maintains close collaboration with the University of Zwickau (WHZ) through a cooperation agreement.
Its goal is to foster cooperation with industry, companies, and local municipalities, as well as support WHZ in research, development, knowledge transfer, and practical training.
The association also offers scientific training courses in technology, business, and social affairs for companies and employees.
