Research project MAN Demonstrates Charging with 3,000 Amperes

From Thomas Günnel | Translated by AI 2 min Reading Time

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MAN has operated a high-current vehicle charging path with 3,000 amperes on the test bench. The technology could significantly reduce charging times for e-trucks.

The companies in the Nefton project have charged a truck with 3,000 amperes of charging current for the first time.(Source:  MAN Truck & Bus)
The companies in the Nefton project have charged a truck with 3,000 amperes of charging current for the first time.
(Source: MAN Truck & Bus)

MAN has achieved a stable charging current of 3,000 amperes for electric vehicles and test bench infrastructure in the "NEFTON 3000" funding project. This could enable future charging capacities of up to three megawatts—and in 10 to 15 minutes, enough energy for 400 kilometers (approx. 250 miles) of range could be delivered to the batteries.

To achieve the high charging capacities in the megawatt range, the project partners redesigned components. The current path was optimized for minimal electrical resistance to minimize heat losses. 

The liquid cooling of cables, connectors, and distribution units was designed by the developers at MAN to ensure that all components operate within the permissible temperature range and can meet thermal and electrical requirements. Contactors and disconnecting devices can withstand the high switching capacities. The project also focused on vehicle-compatible integration, taking installation, weight, and safety into account.

Batteries and Infrastructure Currently Lacking

However, for charging capacities significantly above one megawatt, suitable battery systems are currently lacking, whose cell chemistry, module design, and electrical configuration can efficiently absorb and process such high currents. Additionally, the necessary infrastructure is also missing.

About the NEFTON Project

The consortium of the Nefton project consists of MAN Truck & Bus, AVL, the Technical University of Munich (Germany), Fraunhofer ISE, Prettl Electronics Automotive, the Research Center for Energy Economics, and the Technical University of Deggendorf (Germany).

ein Versuchsaufbau bestehend aus elektrischen Anschlüssen und Kabeln
A part of the test setup at the test benches of the Technical University of Munich and the Fraunhofer ISE Institute in Freiburg.
(Source: MAN Truck & Bus)

The Federal Ministry for Economic Affairs and Climate Action is funding the project. The project sponsor is the German Aerospace Center. In July 2024, the project partners presented a MAN E-TGX with megawatt charging capability. After the project is completed, the Traton Group will continue the work.

The insights gained are being incorporated into the further development of production-ready high-current charging paths. Additionally, they contribute to studies on bidirectional functions and megawatt charging with up to 3,000 amperes.

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