Kinell introduces an HVDC coupling system to extend electric vehicle capabilities

At iVT Expo 2026, Kinell will present a high-voltage direct-current coupling system developed to connect independent high-voltage systems, external electric equipment and range extenders through a controlled interface.

Addressing a growing requirement in special vehicle electrification

As special vehicles move towards electrification, manufacturers increasingly need to extend high-voltage architectures beyond their original fixed scope. A conventional HVDC system typically combines its energy source, power distribution unit, HV bus and connected loads within one permanently integrated electrical system.

In operation, however, a vehicle may need to power an external electric implement, connect an additional subsystem or increase its operating range through swappable batteries or a range extender. Kinell’s approach places the functions required for coupling, operation and decoupling in a dedicated subsystem. This allows the two HV systems to remain largely unchanged, while the coupling solution is configured for the individual application.

More than a physical high-voltage connection

Safely connecting two high-voltage systems requires active management throughout the complete process. Before the connection is established, the interface must verify that operating conditions are safe. It must then manage the connection, monitor the systems in use and control the disconnection sequence.

The Kinell solution can check connector engagement and insulation resistance, manage pre-charging and voltage balancing, and monitor values including power flow and temperature. It is also designed to respond to events such as unintended plug disconnection or interface overload, protecting both users and the connected HV systems.

A typical architecture includes a coupling unit with sensing and actuation functions, integrated DC/DC conversion when two active HV systems are connected, a safety coupling controller and a suitable high-voltage connector. The connector incorporates safety functions such as pull-off mechanisms and interlock pins for plug detection.

Demonstrated on a battery-electric MAN 4×4 truck

Kinell has implemented the system on a battery-electric MAN 4×4 truck for agricultural and forestry applications. The installation uses an AEF/ISO 23316-2 high-power interface to connect swappable external HV batteries to the truck’s main high-voltage system as a range extender.

The truck and the external battery units can operate independently. The swappable batteries can also be charged from other power sources, including solar power. Once connected through the coupling system, the two units operate as one integrated HV architecture and energy can be transferred from the external batteries to the vehicle.

The system also supports controlled connection and disconnection while the vehicle is operating. External batteries can therefore be exchanged while the truck’s integrated batteries continue to supply power during stationary operation.

The HVDC coupling system will be presented at iVT Expo on 10–11 June 2026, Hall 1, Booth 1190.