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Maximizing Efficiency In EV Charging With Eaton’s Battery Configuration Switch

Presented by:

  • Mark VanWingerden, Global Product Strategy Manager, eMobility, Eaton

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Mar 12, 2025, 1:15 pm EDT

An oft-cited concern about the transition to electric vehicles is the availability of high-speed Direct Current Fast Charging (DCFC) infrastructure to enable convenient travel beyond the single charge range of today’s vehicles. Many OEMs are considering a move to 800V architecture from the widely available 400V platforms of most mass market EVs.

While this can have benefits to both vehicle efficiency and charging speed, it comes with a problem: much of the installed high-power DCFC infrastructure in the US and Europe is limited to 400 Volt, necessitating additional, costly equipment for an 800V vehicle to properly interface. Eaton's Battery Configuration Switch (BCS) addresses this challenge with an innovative solution integrated into the EV battery pack.

Designed for passenger and light-duty commercial vehicles, the BCS is a bi-stable device that efficiently transitions pack voltage between 400 and 800 volts to maximize charging speed on all publicly available infrastructure.

In its normal operating mode, the BCS connects two 400-volt sub-packs in series to achieve 800 volts. When a reduced voltage is needed, it reconfigures the battery into two parallel 400 Volt sub-packs, allowing the EV to charge efficiently on 400 Volt DC fast chargers. This reconfiguration capability eliminates the need for multiple contactors, busbars, and harnesses, reducing cost and complexity while enhancing charging performance.

The BCS also enhances safety by using an internal rotary switch to prevent short circuits from collisions, software bugs, or contactor malfunctions. It maintains a stable position without low voltage hold current, improving vehicle efficiency and ensuring functionality even if low voltage power is lost.

Join this webinar to learn about how Eaton's BCS represents a significant advancement in EV technology, offering a robust, efficient, and cost-effective solution for battery pack voltage reconfiguration, underscoring Eaton's commitment to innovation and excellence in power management.

Now available to watch on-demand: Register for this webinar to watch a recording of the presentation and audience Q&A, and download the presentation slides.


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Free EV Engineering Webinars
The sessions from our Spring 2025 EV Engineering Conference are now available to view on-demand. Register for a session below to watch the recording and download the presentation.

See Also: The December 2024 EV Infrastructure Virtual Conference is now available on-demand.

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