This innovative, 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.

“At Eaton, we’re leveraging our extensive background in developing electrified mobility solutions to launch this promising new technology. In partnership with Munich Electrification, which specializes in developing cutting-edge battery management systems,” said Mark Schneider, president, Eaton’s eMobility. “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.”

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

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.

“We are thrilled to collaborate with Eaton in launching this groundbreaking new technology developed by our outstanding R&D team,” said Uwe Wiedeman, managing director, Munich Electrification. “Munich Electrification’s legacy of innovation in the EV battery industry combined with Eaton’s expertise in electrical switching and automotive manufacturing is helping us to solve our customers’ biggest challenges together.”

Eaton BCS Technology

Learn about Eaton’s BCS technology and other vehicle electrification solutions.

Eaton is an intelligent power management company dedicated to protecting the environment and improving the quality of life for people everywhere. We make products for the data center, utility, industrial, commercial, machine building, residential, aerospace, and mobility markets. We are guided by our commitment to do business right, to operate sustainably, and to help our customers manage power ─ today and well into the future. By capitalizing on the global growth trends of electrification and digitalization, we’re accelerating the planet’s transition to renewable energy sources, helping to solve the world’s most urgent power management challenges, and building a more sustainable society for people today and generations to come

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Intelligent power management company Eaton announced it will showcase a broad range of innovative solutions for hydrogen-powered commercial vehicles September 17–22 at IAA Transportation 2024 in Hanover, Germany.

Eaton’s hydrogen recirculation blower cycles surplus hydrogen to the stack’s inlet, which extends system longevity through anode purging. (Photo: Business Wire)

“Eaton believes that hydrogen can play a significant role in decarbonizing commercial vehicles,” said Scott Adams, senior vice president, Global Products, Eaton’s Mobility Group. “Whether a vehicle is powered by hydrogen fuel cells or a hydrogen internal combustion engine, Eaton’s broad range of innovative solutions makes us a valuable supplier partner.”

Eaton TVS technology improves fuel cell performance

Recirculating excess hydrogen through the fuel cell stack is critical for achieving high efficiency in fuel cells. Based on Eaton’s TVS technology, its hydrogen recirculation blower cycles surplus hydrogen to the stack’s inlet, extending system longevity through anode purging, managing water, and reducing cold start issues while maximizing hydrogen utilization by improving efficiency and stack responsiveness.

H2 ICE engines need significantly more air for the combustion process. Eaton’s TVS supercharger provides the ability to produce instant air flow at low engine speeds. It can be disengaged to reduce parasitic losses when not needed. And can be optimized to complement a turbocharger in super-turbo applications.

Hydrogen ICE solutions present challenges requiring innovative solutions

Hydrogen-powered internal combustion engines pose unique challenges that fall squarely within Eaton’s area of expertise – engine air management.

H2 ICE engines have higher combustion chamber temperatures compared to diesel engines. Making them susceptible to surface auto-ignition or knocking. Eaton is one of the largest global producers of engine valves. They have leveraged extensive experience to develop its next generation of hollow valves. Designed specifically for commercial vehicles and hydrogen-powered applications. The innovative design of the new hollow valves results in lower temperatures. Which reduces the risk of engine knock and allows the valve to be produced with more cost-effective materials.

Hydrogen internal combustion vehicles require robust engine brakes

H2 ICE engines need more engine braking due to their low compression ratio. Eaton’s 1.5 stroke engine brake delivers 40% more braking power at low speed compared to a conventional engine brake. Testing has shown that the combination of an Eaton supercharger and 1.5-stroke engine brake provides additional braking power of up to 20%.

For more information on Eaton’s commercial vehicle market solutions, visit Hall 21, Booth B22 at IAA Transportation 2024.

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