eCoupling system

Customer challenge

Manufacturers of e-vehicles or e-mobile machines (e.g., eTrucks or eTractors) are required to provide a safe, pluggable High-Voltage connection to detachable HV consumers (e.g., eTrailers or eImplements) or to detachable external HV sources (e.g., connectable range extenders, swappable power banks or eTrailers with recuperation). For the safe operation of this pluggable HV interface, active HV safety functions and optionally a conversion of different HV voltage levels are required.

System description

The Kinell High-Voltage coupling system provides a validated and easy-to-integrate HV subsystem that enables the connection, operation and isolation of two separate HV systems for uni- or bidirectional electrical power transfer. It comprises:

an High-Voltage coupling module with contactors, pre- and discharge functions and sensors
a coupling control unit for coordinating the HV connection setup, monitoring the ongoing operation of the interface and the controlled decoupling process of the two HV circuits
an optional HV DC/DC converter for voltage equalization of two HV systems
an LV wiring harness that links the control interface of the eVehicle and the components of the coupling system with each other
an HV cable set for connecting the HV interface of the eVehicle (ePTO) with the coupling module and the HV socket

System diagram

Basic version

Plugable interconnection of an active HV system (eVehicle) with an HV socket for a detachable passive HV consumer.

Typical applications

Customer Benefits & System Features

Integrated coupling control

Dedicated coupling controller, which receives the higher-level connection instructions from the e-vehicle and handles the detailed coordination of connection set-up and disconnection as well as the continuous monitoring process.

Secure coupling process

Preliminary check of the HV safety of the HV circuit to be connected by integrated insulation resistance measurement, unipolar connection and active precharging before all-pole connection of the HV connection by integrated contactors.

Continuous HV connection monitoring

Continuous monitoring of voltage, current, temperature and plug pilot status.

Secure disconnect

Controlled HV-contactor opening followed by active discharging upon eVehicle request or emergency release under load in case the HV plug is removed unintentionally.

Ag compatibility (ISO 23316) interoperability

Validated compatibility with high-performance electrical interface 700 V DC / 480 V AC for tractors and machines for agriculture and forestry.

Options available

An additional DC/DC converter allows the coupling of two KV systems with different voltage levels or the connection of another active HV system (range extender). The HV coupling process can be controlled directly using a dedicated HMI.

Single point of contact

Defined responsibility for the components contained in the system, the system functions and the interfaces to the eVehicle / eImplement.

Robust

Robust and reliable system design and component design for rugged applications.

Options

DC/DC-Inverter PTO

Integrated DC/DC-Converter for the connection of two HV-System with different HV-levels or two active HV-Systems (e.g. Range Extenders)

HMI

Additonal CAN-HMI (Keypad) for (additional) decentralized control of HV-connection.

Technical features & data

HV connection

400 – 850 VDC
175 A cont
70 – 140 kW

Coupling controller

Control interface to eVehicle
According CAN | J1939
Power supply 12V | 24V

HV plug

AEF / ISO 23316-2 HV power socket with integrated disconnection function

HV coupling functions

All-pole HV-connectors
Active pre- and discharge
Current, Voltage and Isolation Monitoring

DC/DC-converter

Conversion 400 V to 800V System
Voltage Lowside 0.,.520 VDC
Voltage Highside 450..850 VDC