CharIN_兆瓦充电系统MCS2.0白皮书-2025-07-技术资料_20页_1mb

报告摘要

CharIN White Paper Megawatt Charging System (MCS) Summary

Core Content

The CharIN White Paper on the Megawatt Charging System (MCS) outlines the technical and non-technical requirements for the development and implementation of MCS in the battery electric commercial vehicle industry. It provides recommendations for standards bodies and solution suppliers to ensure a safe, reliable, and efficient charging system that supports high power and fast charging.

Main Points

1. Importance of MCS to the Commercial Vehicle Industry

Key Technologies for Adoption: Increased range and decreased charge times are critical for the widespread acceptance of battery electric commercial vehicles.
MCS Benefits:
- Enables faster charging by increasing the range gained per minute of charging.
- Improves communication robustness, reducing downtime during failed charging events.
Duty Cycle Considerations: MCS allows commercial vehicles to utilize mandated break times more effectively, supporting longer daily driving distances.

2. Public Charging Considerations

Accessibility: MCS chargers must be accessible to large commercial vehicles that require drive-through capabilities.
Recommendation: Refer to the "Charging Site Recommendations" Whitepaper for further details.

3. Provisions for Automation

Human-Operated Dominance: MCS infrastructure is primarily human-operated, but automated coupling is possible and should be considered for future integration.

Key Technical Requirements

1. Communication

Communication Topology: Based on the OSI model, MCS defines a robust communication layer.
Physical Layer: CharIN recommends using 10Base-T1S (IEEE802.3) Ethernet for MCS communication.
- Advantages Over PLC:
  - Reduced Collisions: PLCA (Physical Layer Collision Avoidance) uses CSMA/CA to avoid collisions, improving throughput and reliability.
  - Improved Throughput: No collisions mean more efficient data handling.
  - Enhanced Reliability: Equal transmission opportunities for all nodes.
High-Level Communication Protocol: ISO 15118-20 is recommended as the exclusive protocol for MCS due to its robustness and security features (e.g., TLS 1.3).
- Security Considerations: While TLS 1.3 is mandatory, exceptions may be considered in controlled environments (e.g., private or depot-based charging) with proper risk assessments.

2. Electrical Requirements

Electromagnetic Compatibility (EMC):
- Tests using single pair Ethernet (SP-Ethernet) showed that unshielded twisted pair (UTP) is sufficient for anticipated noise levels.
Isolation & Safety:
- MCS is designed to be galvanically isolated from the grid.
- Transient voltage between HV+ or HV- and PE is limited to 2.5 kV by the EVSE.
HV Touch Safety:
- MCS follows IPXXB standards to prevent contact with high voltage surfaces.
Temperature Limits:
- Maximum Pin/Socket Temperature: Recommended to be 100°C to avoid safety risks and ensure material compatibility.
- Surface Temperature Limits:
  - Metal parts: ≤ 50°C
  - Non-metal parts: ≤ 60°C (for grasped parts), ≤ 85°C (for touched but not grasped parts)
Short Circuit Protection:
- Peak current limit: 70kA (between DC+ and DC-)
- Time-current product: 12MA²s
- In case of two faults, peak current is limited to 55kA and 11MA²s
Bus Voltage Range:
- Recommended range: 400–1250 VDC
- Full range support is essential to ensure compatibility across all vehicles and infrastructure.
Maximum Current:
- Tested up to 3000A DC, with active cooling recommended for high current applications.
Minimum Current:
- Determined by permissible error limits per IEC 61851-23-3.
Thermal Management:
- Vehicle Responsibility: Comply with its own temperature requirements.
- EVSE Responsibility: Comply with temperature requirements for the EVSE and cable/connector.
- Communication of current and voltage limits is required for EVSE to EV interaction.
- EVSE should support power ratings up to 40°C ambient temperature.

3. Hardware Specifications

PE Pin Size: 8mm diameter for the PE pin in the MCS connector.
PE Wire Size:
- Minimum cross-section: 25mm² to withstand short circuit current of 11MA²s.
Insulation Requirements:
- Derived from existing standards (e.g., ISO 5474, IEC 61851-1, IEC 61851-23-3, IEC TS63379).
Touch Current Protection:
- Y-capacitance limits are defined based on voltage ranges:
  - For 1078 < Vdc ≤ 1250 VDC:
    - $ C_{\text{system}} = \ln(0.5 \times Vdc + 75/758) - 0.007 $
    - $ C_{\text{yEVtotal}} = 0.5 \times C_{\text{system}} $
    - $ C_{\text{yEVperDcline}} = 0.25 \times C_{\text{system}} $
  - For Vdc ≤ 1078 VDC:
    - $ C_{\text{system}} = 30 \mu F $
    - $ C_{\text{yEVtotal}} = 15 \mu F $
    - $ C_{\text{yEVperDcline}} = 7.5 \mu F $
Auxiliary Low Voltage Supply:
- Not recommended as a mandatory feature but should be considered as an optional feature.
- In the absence of auxiliary supply, EVSE should use UPS or similar for communication during power outages.
- Vehicles with low voltage battery issues can use jumper cables or jump boxes to start charging.

4. Coupler and Connector Design

Coupler Retention:
- Electrically activated/actuated lock to ensure connector remains engaged during normal and fault conditions.
- Feedback to EV is required.
- Should be integrated into the inlet side, up to 3 locations.
Insertion / Extraction Force:
- Recommended force: 100N, same as IEC 62196.
Drop Test Requirement:
- MCS connectors must be robust and able to withstand dropping conditions, especially in harsh environments.
Mating Durability:
- No-load endurance testing is required, with specifications varying by region.

Conclusion

The MCS is a critical enabler for the commercial vehicle electrification, offering significantly higher charge rates and improved communication reliability. CharIN recommends the adoption of ISO 15118-20 for communication, 10Base-T1S Ethernet for physical layer, and a 400–1250 VDC voltage range. The design emphasizes safety, robustness, and user experience, while discouraging the use of adapters to ensure consistency and reliability across the system.

展开完整摘要