“The transition to heavy-duty electric mobility requires charging infrastructure that delivers both high power and dependable operation,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “The C330 megawatt charging contactor can safely switch the power levels required to recharge commercial vehicles within a typical driver break. With the C330, we enable customers to develop, equip and scale future-ready high-power charging systems that maximize charger availability, reduce costly downtime, and improve fleet utilization and total cost of ownership."

The Eddicy C330 is a single-pole, bi-directional DC contactor and the industry’s first rated for up to 1,500 V and continuous currents of up to 3,000 A. Featuring silver contact pills and an innovative contact system, the C330 achieves an industry-leading contact resistance of just 40 µOhm. This significantly reduces contact heating, power losses and cooling requirements. With separate contact systems for switching and current carrying, the C330 protects the main current path from the negative effects of electrical arcing, delivering outstanding safety, endurance and longevity.

The bi-directional contactor features an open-air-isolation concept with permanent magnetic arc blow-out that prevents rupture even under the most severe failure conditions. It can withstand short-circuit currents of up to 30,000 A for 5 ms without rupturing or damaging surrounding components.

The Eddicy C330 is designed for use in charging stations, energy storage systems and photovoltaic applications. CE, CCC and UL certifications are currently underway and are expected by September 2026.

Discover the Eddicy C330 contactor and meet Schaltbau’s experts at

• The Battery Show Europe (June 9–11, 2026)
  Messe Stuttgart, Hall 4, Booth E71
   
• Power2Drive Europe (June 23–25, 2026)
  ICM Munich, Hall C6, Booth C6.373

As the transition to electric mobility and climate-friendly long-haul transport accelerates, Schaltbau is expanding its portfolio for stationary and mobile charging infrastructure. The new C305 and C805 contactors support the current MCS power class at 1,500 A, while the C330 and C830 are 3,000 A bidirectional contactors designed for the future power class of MCS high-power DC charging.

“Megawatt charging allows electric trucks to charge during the length of a driver’s break, making long-haul electric freight economically competitive with diesel,” says Helmut Pusch, CEO of Schaltbau GmbH Group. “While vehicle readiness is advancing faster than infrastructure, we are now seeing the first MCS pilot projects and corridor initiatives in North America. With the industry’s first contactors rated for 3,000 A, we reaffirm our commitment to pioneering high-performance DC solutions that support the electrification of mobility and long-haul transport.”

All megawatt charging contactors feature a compact, open-air-isolation concept that prevents rupture even under the most severe failure conditions and short-circuit currents, preventing damage to surrounding components. They withstand short-circuit currents of up to 30,000A for 5ms without rupture and, thanks to their fully bidirectional capability, are well suited for vehicle-to-grid applications.

In addition, their ultra-low contact resistance delivers superior performance with minimal heat generation. As power losses increase quadratically with current, minimizing contact resistance in high-current megawatt charging applications is essential to ensure efficient energy transfer, to protect surrounding components and batteries, and to maintain competitive total cost of ownership — enabling up to 25% energy cost savings through reduced power losses. Since the switching and current-carry circuits are separated inside the C330 and C830, the contact resistance stays stable over time independently of the respective working profile.

For more information about the event, visit here.  

In high-current applications, contactors are designed to carry electrical current as efficiently as possible — to transmit energy, not to lose it along the way. Ideally, all input power would pass through the device without loss. In reality, however, current flowing through a resistive medium, any energized coil, and every closed contact introduce unavoidable electrical losses. These losses do not disappear; they are converted into unwanted heat.

More importantly, heat is not just a by-product in electromechanical components; it is one of the primary limiting factors for thermal performance and overall stability. To keep the contactor safe and prevent damage to plastic components, both the manufacturer and the user face challenges: the manufacturer must select appropriate materials and design an optimal geometry, while the user must ensure proper integration, including correct cabling, adequate cooling, etc. Additionally, heat translates into higher total cost of ownership: dissipated heat is nothing other than energy (and therefore money) lost along the way. Increased cooling demands can further add to system complexity and cost.

Especially in high-current DC applications, even minimal resistance leads to measurable temperature rise. While this is physically unavoidable, it must be carefully managed and mitigated through smart contactor design that takes the major loss sources at the contactor level into account.

Learn more about the main loss mechanisms in contactors and their impact on performance in our recent webinar “Heat sources and losses in electromechanical contactors”.

Choosing the right contactor parts and materials

When it comes to thermal management, not all materials within a contactor are created equal. While metals and technical ceramics in a contactor are relatively resistant to high temperatures, plastics (e.g., housing or contact bridge carriers), coil coatings and electronic components (such as economizer PCBs) are far more heat-sensitive, with adverse effects beginning at temperatures above 120 °C.

In the event of overheating, these materials and components can soften, melt, cause unwanted chemical effects, decompose, or age rapidly. Consequently, the maximum allowable and continuously possible inner temperature of a contactor, can only be as high as the maximum temperature the most heat-sensitive component within the device may tolerate. Minimizing losses at the main contacts and coil, along with using high-quality materials that are relatively temperature-resistant, is essential to maximize the performance, safety, and service life of the contactor and the application in which it operates.

Learn more about the difference between inner and outer contactor temperature – and why terminal temperature is the key indicator of contactor heat loss – in our recent webinar “Heat sources and losses in electromechanical contactors”.

Thermal behavior and application-specific evaluation

Ultimately, all loss mechanisms within an electromechanical contactor contribute cumulatively to internal heating, and terminal temperature remains the key practical indicator of thermal performance, which must never exceed the specified limits. Additionally, thermal behavior is strongly influenced by cooling conditions, current levels, duty cycle, and connection design, making each application unique. For this reason, contactor selection cannot rely on nominal ratings alone: each use case must be evaluated under worst-case conditions, and testing under real operating parameters remains the most reliable methodto verify long-term suitability, safety, and performance.

Looking for the right contactor for your application? We are ready to provide the technical and application support you need.

Tasked with feeding a growing global population, farmers are among those most directly affected by the consequences of climate change. At the same time, agricultural processes such as crop and livestock production account for around 11 percent of global greenhouse gas emissions.¹ According to McKinsey, “To remain on a 1.5° pathway, agriculture will have to cut its overall emissions from 14.4 metric gigatons (Gt) of CO₂ equivalent (CO₂e) to 3.1 GtCO₂e by 2050 — almost 80%.”² Electrification and smart farming technologies offer farmers a practical path forward, helping them maintain yields while reducing energy costs and lowering their carbon footprint. 

Achieving this pathway in agriculture, however, will require action across the entire value chain, including reducing food loss and waste and encouraging dietary shifts.³ When it comes to measures that directly support on-farm decarbonization, the electrification of agricultural machinery powered by renewable energy ranks third among the 28 measures identified in McKinsey’s “The agricultural transition: Building a sustainable future” report.⁴ Electrified tractors or solar-powered irrigation systems are therefore important elements in the transition toward more sustainable agriculture. But they depend on advanced electromechanical components that can deliver reliable performance under harsh field conditions. 

Electrifying farming equipment: Opportunities and challenges 

While the electrification of agricultural machinery is still in its infancy, electric yard loaders, vineyard tractors, and farm tractors already deliver strong performance in areas where low noise levels or emission-free operation are essential. The trend toward further electrification of heavier tractors and trucks is also continuing unabated. Many countries have introduced tighter CO₂ and NOₓ limits for non-road mobile machinery, and advances in battery energy density, high-voltage DC architectures, and power electronics are making electric equipment more viable.  

Despite the higher purchase price of battery-electric machinery, which still poses a barrier to broader adoption, these vehicles offer significant operational advantages. Their electric drivetrains contain fewer moving parts, resulting in lower maintenance requirements compared with diesel-powered equipment, particularly when it comes to servicing oil, filters, and exhaust treatment systems. Electric drives also deliver instant torque, reduced noise and vibration, and seamless compatibility with autonomous systems and robotics, making them ideal for smart and precision farming applications. 

Electric tractors are also more efficient than diesel-powered tractors, whose engines suffer from poor fuel efficiency when idling or operating below optimal RPM levels. This efficiency advantage becomes even more pronounced when electric tractors are powered by solar or wind energy. The well-to-wheels (WTW) efficiency of a combustion engine tractor reaches only between 25 to 37%, whereas an electric tractor reaches in-between 39 and 67% when fed from wind and solar farms or between 42 and 72% when using on-farm rooftop PV systems where no conversion losses occur. As Gade et al. note, “The (diesel) engine wastes 75% of its energy and generates noise as an undesirable result. [An electric motor] has near-perfect energy efficiency and can regenerate energy while braking.”⁵ Nevertheless, electric tractors require larger batteries to achieve a respectable range, and their electric powertrains still come with a higher upfront purchase price. 

High-power electromechanical components in agricultural applications 

What sets electric vehicles, machinery, and charging systems in farming environments apart from on-road e-mobility are the extreme conditions components must withstand: dust, vibration, voltage spikes, temperature fluctuations, and high humidity all come into play Electrified machinery therefore requires rugged, long-life switching and interconnection solutions, along with effective inrush-current management and arc suppression in DC systems. Reliable contactors and connectors help minimize unplanned downtime and ensure safety in high-voltage applications. While Eddicy contactors from Schaltbau switch the load circuit on and disconnect it safely, the robust Eddicy connectors ensure secure, long-lasting connections even under severe exposure to dust, moisture, vibration, and temperature extremes. 

In a battery-electric tractor, connectors form the critical interface that safely links the high-voltage battery pack to inverters, motors, and auxiliary systems. By maintaining low-resistance, stable electrical contact over thousands of mating cycles, they support modular system design, long-term reliability, and maximum machine uptime. When charging electrified agricultural machinery, the connector becomes the key interface between the vehicle and the charging infrastructure. A charging connector provides secure mechanical coupling and precise electrical contact, enabling consistent high-current flow without overheating or unnecessary energy losses. It also incorporates safety functions such as interlock circuits and communication pins, ensuring that charging can begin only once the connector is fully latched and both the charger and the vehicle have verified system readiness. 

Ready to power agricultural electrification: Eddicy’s HV connectors 

Eddicy HV connectors from Schaltbau provide reliable and safe power transmission up to 1,800 VDC and 470 A, enabling them to handle the high-current demands of electric tractors and large battery packs. Their low contact resistance minimizes heat buildup during long duty cycles or sustained charging. The connectors are IP69K-certified and engineered for a high number of mating cycles. Because of their robust, modular design and comprehensive protection against accidental contact, they are well-suited for equipment exposed to slurry, mud, dust, fertilizers, humidity, or high-pressure washing.  

Their one-hand locking mechanism enables secure coupling even when wearing gloves or working in dirty conditions. An optional switching element in the socket housing signals when the connector is correctly plugged in. The modular arrangement of power and signal contacts also allows flexible integration on both the vehicle and charger side, for example in battery–inverter connections, battery–DC bus interfaces, onboard charging ports, or off-board charging systems. 

Eddicy HV connectors combine high-current capability, IP69K environmental sealing, vibration-resistant mechanics, and integrated safety functions including insertion feedback. This makes them equally well-suited for onboard electrified tractor powertrains and for high-power charging interfaces, where reliability under harsh outdoor conditions and safe operator handling are essential. 

With the advancements of agricultural electrification, new charging solutions, and renewable energy integration, such as solar-powered charging stations, the importance of safe DC switching and reliable connections for farm-wide energy management is increasing. If the 1.5° pathway is consistently followed in agriculture, local energy ecosystems in farms could eventually see renewable generation, storage and electric equipment work together.  

Learn more about our solutions for agricultural applications and how we can support your electrification goals here.

References:

1. Statista, Agriculture emissions worldwide - statistics & facts, July 7, 2025.
2. McKinsey, The agricultural transition: Building a sustainable future, June 1, 2023, p. 12.
3. Ibid., p. 3.
4. Ibid., p. 24.
5. Gade, C.R. et al., Towards sustainable farming: A state of art review on electrification of a farm tractor, in: Results in Engineering, Volume 25, March 2025, p.3.

First introduced at the InnoTrans fair 2024, the PAD 41 passenger alarm handle has been developed as the direct successor to Schaltbau’s proven PAD 40 series to address increasing requirements from rail operators for longer inspection intervals, improved serviceability and greater functional flexibility. At the same time, PAD 41 maintains full mechanical compatibility with existing PAD 40 installations, so that devices can be replaced without reworking the mounting surface. This allows straightforward retrofitting in existing fleets as well as integration into new vehicle platforms. 

A central enhancement of PAD 41 is its increased B10d value, which enables substantially extended inspection cycles for the passenger alarm handle. The B10d value, a reliability metric that describes the number of actuations at which fewer than 10% of devices are expected to experience failure, led to recommended inspection cycles of 6 months for PAD 40. With a B10d value of 30,000 actuations, the successor PAD 41 now supports inspection intervals aligned with regular vehicle maintenance cycles of two to three years, depending on operating conditions. As a result, both maintenance effort and vehicle downtime are reduced without compromising safety. 

 “Passenger alarm handles are rarely actuated in service, but they must function reliably after years of exposure. PAD 41 is designed for use in passenger rail vehicles where predictable inspection cycles, simplified maintenance and long-term reliability are critical selection criteria,” says Helmut Pusch, CEO of Schaltbau GmbH Group. “For operators, PAD 41 offers a clear transition path: a direct replacement for PAD 40 with no interface changes, but with measurable improvements in inspection cycles, service effort and configuration flexibility.” 

PAD 41 introduces a modular design, in which housing components and handles can be replaced independently without fully dismantling the device. Maintenance is further simplified through maintenance-free plain bearings which do no longer require regular lubrication as well as plug-in bolt mounting for snap-action switches. In contrast to PAD 40, the PAD 41 supports up to four S826 or S870 snap-action switches. 

Schaltbau’s PAD 41 passenger alarm handles are available in numerous customer-specific variants and options, including two housing designs (a classic version and a version with rounded outer edges), an emergency hammer with interlock hammer holder, LED indicator lights, individual labelling or an optional remote reset, allowing both manual reset and reset via electrical input.   

Learn more here

Schaltbau has described NExT Factory not just as a milestone for the company, but for the industry. What makes it so significant in your view?

Helmut Pusch: To me, it represents a functioning model of what the future of industrial production could — and should — look like. The factory is built around a new energy logic. Instead of relying on conventional AC grids, we have implemented a DC microgrid that allows us to operate more efficiently, reduce conversion losses, and integrate renewable energy far more effectively. In doing so, it aligns perfectly with the vision of the All Electric Society – a world in which energy is generated renewably, used efficiently, and distributed intelligently across sectors. NExT Factory proves that this is not an abstract idea. It is already possible today, even in a complex manufacturing environment.      

If you were to summarize the first two years in a nutshell, what would you say?

We have been able to demonstrate that it is entirely possible to run a manufacturing site powered by direct current. That in itself is a pioneering achievement, and I commend the entire team for turning this vision into reality. NExT Factory is a testament not only to Schaltbau’s engineering excellence, but also to the unwavering grit and perseverance in working with authorities and grid operators.

No stumbling blocks?

Of course, we faced some initial challenges, including fine tuning the interaction between our DC grid and the public AC grid, and adjusting automation processes to run smoothly in a DC environment. But we addressed them by working closely with our technology partners, investing in employee training, and making incremental improvements. Within a short time, we were able to stabilize operations and ensure seamless production. 

 

Let’s talk numbers: What were your initial energy saving targets for NExT Factory and have those been achieved?

When NExT Factory began operations, our goal was to save up to 15% in energy annually with our direct current (DC) microgrid. The photovoltaic system on the factory roof generates around 1.3 MWp of energy per year which is directly fed into the DC microgrid without being converted into alternating current, as is typically the case. In practice, we have exceeded this target: thanks to reduced conversion losses and higher system efficiency, our PV systems deliver an 8% efficiency boost compared to AC, and DC-coupled battery systems avoid a further 3–4% in energy losses.

In addition, we have set up the factory to function like a kind of circular economy for energy. By implementing the DC grid alongside intelligent energy management and storage, we targeted a 35% annual reduction in energy costs — and this is exactly what we are achieving today. Our average annual self-sufficiency rate currently stands at around 66%, based on renewable electricity sourced and consumed on site.

You mentioned the vision of the „All Electric Society” earlier. In what way is the factory exemplary to it?

First of all, the All Electric Society envisions a shift away from fossil fuels, with energy supplied primarily from renewable sources. In line with that, we operate a fully electrified production facility with minimal CO₂ emissions. The second key principle is increasing energy efficiency and achieving energy savings. We significantly reduce AC/DC conversion losses and manage energy far more intelligently to maximize self-consumption, for instance, by directly reusing recuperation energy in our logistics warehouse system, which has reduced peak loads by up to 85%. We also saved 25% in materials during construction, such as copper, because higher voltages in DC allow for significantly smaller cable cross-sections. And thirdly, I believe that NExT factory shows that sector coupling is possible on a factory scale.

What do you mean by that?

In the context of the “All Electric Society”, sector coupling refers to the integration and coordination of different energy sectors, such as electricity, heating, transportation, and industry, so they can exchange energy and make more efficient use of available resources. At the NExT Factory, these sectors do not operate in isolation but are interconnected. We generate electricity from solar power. We store excess power not only in our DC battery storage system, but also in heat – the factory has a thermal storage capacity of 10 MWh. The factory’s DC grid also supplies power to the charging infrastructure for electric vehicles, forklifts and electric industrial trucks. In other words, we are maximizing the use of renewable energy by linking it directly to our various energy demands.

What’s next for the NExT Factory?

NExT Factory sets a benchmark and serves as a scalable model for sustainable manufacturing. We hope to see broader adoption of similar DC microgrid systems — more “NExT Factories” — which could significantly reduce CO2 emissions across the sector and help advance the vision of the All Electric Society. Since our opening, we have welcomed more than 20 international visitor groups from across the globe, including many industry peers. I am confident we will see growing interest in and adoption of DC technology in industrial production environments – and we are happy to support these initiatives by sharing our experience, consulting on projects, and supporting others with our pioneering AI-driven EMS solution or our contactor and smart circuit breaker portfolio. 

Learn more about the NExT factory, DC microgrids and intelligent EMS here. 

Schaltbau, a global leader in direct current technology (DC), opened its NExT Factory flagship site for sustainable and intelligent manufacturing in Velden, Germany. The factory has been in full operation since September 2023, serving as a production site for the company’s advanced electromechanical components and systems for DC power applications, which are distributed to energy, e-mobility and energy customers worldwide.

“We are very honored that our NExT Factory has been recognized on Germany’s TOP TENs Energy Efficiency List. Energy efficiency, digital innovation, and direct current technology are at the heart of competitive, sustainable and more resilient industrial production,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “No company can travel the road toward the All Electric Society alone. It requires knowledge and technology transfer, as well as pioneering projects like NExT Factory. It is a scalable model that will hopefully inspire many more solutions for smart, efficient and green industry.”

Energy and resource efficiency are central to NExT Factory’s design. It integrates a 1.3 MWp roof-top photovoltaic system directly into a DC microgrid, combined with an intelligent AI-supported energy management system and battery (300 kWh) and thermal storage (10 MWh). This innovative approach eliminates conversion losses between alternate and direct current, reduces peak loads by up to 85%, and allows the facility to operate with 66 percent renewable energy of its own generation (net annual basis) –

all resulting in up to 35% annual energy cost savings.

Schaltbau’s NExT Factory has previously been recognized with multiple awards, including the German Innovation Award 2024, Dena Energy Efficiency Award 2024, the German Excellence Award 2025 as well as the FREDDIE AI Industrial Award 2025. These accolades reflect the company’s commitment to driving energy efficiency, sustainability, and innovation in DC power solutions and manufacturing.

When it comes to heavy-duty freight and long-haul commercial vehicles, the opportunities and challenges of electrification are equally significant. Their impact on the climate is considerable: Heavy-duty vehicles (HDV) account for more than a quarter of greenhouse gas emissions (GHG) from road transport in the European Union alone and for over 6% of total EU GHG emissions.¹ Against the backdrop of global climate targets and the urgent need for decarbonization, electrifying road transport is essential. Megawatt charging is a key enabling technology to accelerate this shift before the end of the decade, particularly for vehicle classes that lack fixed routes or overnight depot-charging options (vs. e-buses or light commercial e-vehicles for inner-city or regional transport).

The promise of MCS: “Diesel-like” charging times

Although various high-power charging solutions with hundreds of kilowatts are already commercially available, multi-megawatt charging for heavy-duty vehicles is only now being developed and deployed by OEMs. While megawatt charging standards (MCS) level 2 targets up to 1.5 MW (1,500 A at up to 1,000V), MCS level 3 aims for up to 3 MW or more with current up to 3,000 A.

This could solve a critical pain point in electrification: charging times would align with typical work patterns and driver regulations. In the EU, for example, drivers are permitted 4.5 hours of driving before a mandatory 45-minute break. Under today’s CCS high-power charging standard, a 600 kWh truck charging from 10 to 80% state of charge (SoC) takes more than 70 minutes. With MCS, the same truck could charge in about 25 minutes.² Such charging window aligns with mandatory rest periods and extends ranges, supporting long-distance freight operations without disrupting route schedules.

Thermal challenges in megawatt charging

Yet, the path to HDV electrification faces formidable roadblocks in the form of regulatory, infrastructural, and technological challenges.³ One of the most critical technological challenges is the heat generated during the charging process. Excessive heat can damage cables, connectors, and other components, or even cause high-fault currents and fire hazards. Most importantly, batteries degrade much faster when repeatedly charged under hot conditions, reducing range, lifespan and the residual value of e-trucks.

But how does so much heat build up? Because every point of internal resistance along that long chain of connections from the charging port into the batteries causes energy losses and inefficiencies. And since megawatt-level chargers push 10 to 30 times more current than a typical home EV charger, and power losses grow quadratically with current, even small amounts of resistance generate significant heat.  

In a recent Schaltbau webinar, this was illustrated using the example of an average industry contactor with a 200 µOhm contact resistance. At CCS high-power charging levels, such contactor would generate 50 W of heat loss. In an MCS scenario at 1,500 A, this heat loss rises to 450 W. “That’s enormously high,” says Pavel Tomashev, Product Manager at Schaltbau. “That’s roughly the same heat as an iron or hairdryer set to medium power. You wouldn’t like to have several irons within a single switching cabinet⁴."

Technical solutions to overcoming MCS’ thermal challenges

So far, four main solutions have been developed to address thermal challenges in megawatt charging: (1) liquid cooling systems in stationary charging stations, (2) cooled charging harnesses that circulate a coolant directly through the power lines to keep the cables and connectors cool, (3) optimized component design to handle high loads without excessive resistance, and (4) advanced monitoring systems that continuously track temperature and other parameters, allowing for immediate shutdown if conditions become dangerously hot.

Despite the technical potential of cooling or monitoring systems, the business challenge remains: They have the potential to increase the total cost of ownership for heavy-duty EV operators, either by cutting into cargo (i.e. for additional cooling) or, more probable, into budget.

And additional operating costs add up quickly. If you increase charging current five-fold from 300 A to 1,500 A, power losses of a contactor with 200 µOhm grow quadratically by a factor of 25. As a result, the cost of wasted energy in the form of heat increases from around EUR 16 to EUR 362. Offsetting this with a cooling system would add roughly another EUR 340. Altogether, this amounts to about EUR 700/year, caused solely by inefficiencies at the contactor level.⁵

Choosing the right contactor for scalable and reliable MCS deployment

With the extremely high currents in MCS Levels 2 and 3, even the smallest resistance inefficiencies cause a significant portion of the energy intended for the powertrain or battery to dissipate as heat. At the contactor level, minimizing resistance is therefore imperative. Schaltbau has already introduced a new series of bi-directional contactors for Level 2 and Level 3 megawatt charging, designed to ensure efficient energy transfer and competitive total cost of ownership.

The new contactors for both stationary (C305 and C330) and mobile (C805 and C830) applications use silver alloy contact pills to achieve industry-leading contact resistance as low as 40 µOhm, delivering best-in-class performance with minimal contact warming. In practical terms: five times lower contact resistance (compared to average 200 µOhm contactors) also translates into five times lower costs.

The series also features a compact, open-isolation design that ensures robust protection under extreme conditions: permanent magnetic arc quenching without gas encapsulation prevents overheating and overpressure at all times. Even during severe short-circuit events, the contactors prevent system damage and component failure. For example, the C330 can withstand a short-term current of 15,000A for five milliseconds without contact welding — a critical safety benchmark for high-power systems. 

With separate contact systems for switching and current carrying, Schaltbau’s megawatt charging series also offers exceptional long-term contact resistance stability. Thanks to their compact size, these contactors are ideally suited to meet the stringent space requirements of megawatt charging stations, battery storage systems, e-mobility platforms, and other high-power industrial applications. With full bidirectionality, they are also ready for vehicle-to-grid (V2G) charging.

With the industry’s first contactors rated for 3,000A in accordance with the MCS standard, Schaltbau reaffirms its commitment to pioneering high-performance DC solutions that advance the electrification of energy and mobility.

Learn more about our solutions for megawatt charging and how we can support your electrification goals here.

References:

1. European Commission, Reducing CO₂ emissions from heavy-duty vehicles, 2023.
2. Schaltbau Webinar, How to overcome thermal challenges in megawatt charging, May 2025. Another similar calculation can be found in Froese, Michelle, Megawatt charging brings sub-30-minute charging to heavy-duty EVs, in: EV Engineering + Infrastructure, July 8, 2025.
3. For more details on the regulatory and infrastructural challenges, please see Schaltbau Blog, From diesel to direct current: Powering the electrification of commercial vehicles with megawatt charging, May 28, 2025.
4. Schaltbau Webinar, How to overcome thermal challenges in megawatt charging, May 2025.
5. Ibid. Schaltbau’s calculation is based on the average energy cost for industrial customers in Germany in 2024 and the rough estimation of cooling system capital and operating costs.

Schaltbau today announced the launch of its Eddicy R300 high-voltage relay, a compact and robust solution designed for applications where performance, safety, and compliance are critical. Based on the company’s trusted R400 relays in the railway sector, the Eddicy R300 brings proven reliability to new industrial use cases, delivering confidence wherever high-voltage DC testing and insulation with non-active component isolation is required.

Engineered to withstand voltages up to 10,000 V, the R300 is easily integrated into various test environments. The robust and durable device is capable of safely switching currents up to 25 A, comes in single- and double-pole configurations, and combines a space-saving design with outstanding performance. Its large contact pills ensure extremely low contact resistance, minimizing heat generation and significantly reducing the risk of contact welding.

The double contact bridge design provides improved arc extinguishing performance. With a making capacity of up to 200 A, the relay is engineered for long-term durability even under tough operating conditions. An integrated economizer circuit keeps pull-in power consumption below 12 W, enabling direct control with a programmable logic controller (PLC), lowering operating costs and thermal stress while extending service life.

“Reliable isolation and switching in high-voltage DC systems remain among the toughest challenges in modern engineering,” says Helmut Pusch, CEO, Schaltbau GmbH Group. “Our new R300 high-voltage relay extends Schaltbau’s proven DC technology from the rail sector to the field of advanced test systems, ensuring electrical safety by reliably isolating all non-active components during high-voltage and insulation testing. Compact, cost-efficient, and easy to integrate, it offers a dependable solution where a contactor would be oversized.”

The R300 is designed for a wide range of high-voltage and safety-critical applications. In testing environments, it supports HiPot, insulation, PE conductor, and leakage current testing, ensuring reliable and repeatable results. In power electronics, it serves as a pre-charge relay in converter systems, and as a relay for switching measuring points. Unlike competing products, the R300 is a ready-to-use solution, with all necessary components included, eliminating the need for additional purchases and simplifying installation while reducing overall system cost.

Learn more here

Schaltbau, a global leader in direct current (DC) technology, has received the FREDDIE AI Industrial Award in the “Sustainability” category for the AI-based energy management system at the NExT Factory, the world’s first DC factory in Velden, Germany. The award recognizes how the system intelligently connects a wide range of energy sources, consumers, and storage systems, setting new benchmarks in industrial energy supply performance and sustainability.

“AI, sustainability and economic impact go hand in hand. Because no suitable energy management system for DC fed industrial power supplies existed, we developed one ourselves, just as we did when creating the world’s first DC factory,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “This double pioneering spirit defines who we are: when solutions don’t exist, we create them. And then we share them. Our NExT Factory and its AI-driven EMS form a blueprint for the All Electric Society, helping drive the global transition toward smarter, cleaner, and more resilient industrial power systems.”

The idea for an AI-driven energy management originated during Schaltbau’s pioneering project to build the world’s first DC factory. With no existing solution available, the company built its own, extending its innovation from factory concept to the intelligent systems that power it. By directly coupling energy generation from a rooftop photovoltaic system, storage, and consumption on a DC microgrid, conversion losses are minimized, significantly increasing overall system efficiency and reducing costs. Managing such a system, however, is highly complex and cannot be handled with static, rule-based algorithms. Thousands of data points must be processed every second — from power flows and production schedules to weather forecasts, load shifting to sunny periods, and variable electricity tariffs.

The NExT Factory’s EMS, supporting both DC and AC networks, uses artificial intelligence to dynamically learn, recognize patterns, forecast future power consumption, and enable predictive, efficient control of the entire DC energy supply network. The scalable system was developed in-house with a cloud-based backend and a local edge application, and it received funding from the Federal Ministry of Research, Technology and Space under the SynErgie3 project.

The FREDDIE Industrial AI Award, initiated by publish-industry and UnternehmerTUM, recognizes outstanding applications of artificial intelligence in manufacturing and industrial environments. It honors projects that demonstrate how AI can transform industrial processes, enhance efficiency, and deliver measurable value. Award-winning solutions typically stand out for their technical excellence, industrial relevance, scalability, degree of innovation, business impact, and future potential. With both factory concept and the in-house AI-based EMS, Schaltbau continues to share insights and best practices with partners and the wider industry – because advancing DC technology is a collective mission toward a more sustainable future.

Schaltbau today celebrates the two-year milestone of its NExT Factory, a flagship site for sustainable and intelligent manufacturing. Since opening in 2023, the 22,000 m² facility has demonstrated how a DC-powered plant combined with AI-driven energy management can set new standards in industrial performance and sustainability. The factory has already earned global recognition, including awards such as the German Innovation Award and the German Energy Agency’s Energy Efficiency Award as well as a recent nomination for the Freddie Industrial AI Award.

“The NExT Factory is more than a production site – it’s a blueprint for The All Electric Society and the future of sustainable industry,” said Helmut Pusch, CEO Schaltbau GmbH Group. “We’ve demonstrated that energy efficiency, digital innovation, and high-performance manufacturing can go hand in hand. This combination not only makes our production more sustainable, it also provides customers and partners with a concrete example of what the transition to the All Electric Society looks like in practice.”

Energy and resource efficiency are central to the NExT Factory’s design. The facility operates with 66 percent renewable energy of its own generation (net annual basis), thanks to cost-efficient heat pumps that replace the gas systems of the previous site. At the core is an AI-based energy management system (EMS) that controls the factory’s grid. Together with battery and thermal storage, this enables predictive control and continuous optimization. The result: up to 35 percent in annual energy cost savings, while PV systems deliver an 8 percent boost in efficiency compared to AC configurations. DC-coupled battery systems reduce energy losses by an additional 3–4 percent.

Digital innovation rounds out the factory’s achievements. The site features a digital twin of the DC grid and the EMS. These technologies not only improve performance but also provide the flexibility and resilience needed to meet growing customer demands.

As part of Schaltbau’s global production footprint, the NExT Factory also plays a strategic role and international demand while aligning with political and ESG requirements. With 2,000 m² of open office space and 64 assembly lines across custom, small-to-mid-series, and large-series production, the facility produces 38,500 custom pieces, 167,000 small-to-mid-series, and 760,000 large-series products each month. Since its launch, the NExT Factory has implemented several continuous improvement projects, alongside major automation milestones such as a fully automated pre-assembly line for drives, a final assembly line for contactors, and a laser welding machine.

The factory’s supply chain and logistics operations have also advanced rapidly. Demonstrating a commitment to continuous business excellence, several key process improvements have been rolled out with average implementation times of just 12 weeks. At the same time, our sourcing philosophy carefully balances economic, ecological, and social considerations to ensure responsible and sustainable outcomes. Ongoing logistics optimizations continue to lower environmental impact, further reinforcing the site’s commitment to sustainability.

Over the past two years, the NExT Factory has hosted delegations from leading international companies seeking insight into sustainable manufacturing practices and DC factory concepts. By sharing practical expertise and proven approaches, Schaltbau continues to position itself as a trusted partner in helping industry realize the transition to DC-based production. Looking ahead, the facility will remain a cornerstone of innovation, efficiency, and responsible growth.

“We are proud to share our knowledge and experience with other companies seeking to establish DC-based factories,” added Pusch. “Actively supporting this transition is part of our responsibility to accelerate the move toward green industry and sustainable production."

To read more about DC microgrids, EMS, and NExT Factory, visit us here.

Building upon earlier successes of the C303 series, the final series production model leverages advanced open-air isolation technology, ensuring longer service life, higher system safety, and significantly reduced energy costs—up to 25% savings on total cost of ownership (TCO). Featuring enhanced arc suppression, ultra-low contact resistance, and full bidirectional operation, the C303 supports V2G readiness and secure integration into complex energy management systems. The final series version of the C303 has a streamlined design making for easier installation.

“The global demand for energy storage, EV infrastructure, and industrial electrification is projected to grow significantly in the coming decade,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “With the C303 series, we’re responding not only with advanced technology but also with production capacity: engineered, manufactured, and also deployed in our state-of-the-art NExT Factory, where green processes, fully automated lines and multi-shift operations support not only the C303 but a broad range of advanced DC solutions, giving customers  the confidence that we can deliver high volumes without compromise on quality. This combination of German-made excellence, scale and innovation equips our partners to meet today’s extreme demand.”

Engineered for the toughest requirements in e-mobility and energy storage, the C303 combines 1,500 V switching capability with continuous currents up to 500 A in a compact, 0.42 kg design. Its open-air, magnetically blown arc system eliminates the need for gas encapsulation, reducing risk and extending service life even under demanding conditions. With ultra-low contact resistance of just 100 μΩ, the C303 minimizes thermal losses and cuts energy costs by up to 25% in continuous operation. The contactor is available with three optimized magnetic drives — EcoSave with integrated PWM for low holding power, High Efficiency Drive (HED) for maximum coil efficiency, and Precharge for safe inrush current limiting, making it adaptable to a wide range of applications. Safety is reinforced by a mirror contact auxiliary switch (IEC 60947-4-1), ensuring reliable feedback in critical control systems. Rated for operation from –40°C to +85°C, with short-circuit withstand capacity up to 5,000 A for 20 ms, the C303 delivers dependable bidirectional switching for EV fast charging, stationary storage, grid stabilization, photovoltaics, and other high-demand DC applications.

“The C303 isn’t just about technical specifications — it’s about giving our customers confidence in the face of massive demand,” said Pusch. “They need solutions that can scale, run reliably in all conditions, and reduce total operating costs over the long term. That’s what makes the C303 different: it allows system builders to focus on growth and innovation instead of worrying about the limits of their switching technology.”

The C303 series is part of Schaltbau’s Eddicy brand, dedicated to empowering efficient and secure electrification for future-oriented DC applications across diverse industries.

As part of a broader production portfolio, it reflects Schaltbau’s ability to scale and adapt solutions in line with evolving customer requirements. 

Find detailed information about the C303 series or inquiries on availability here.

In fact, V2G sits at the intersection of two converging challenges: first, the accelerated electrification of transportation which increases electricity demand considerably, and second, the growing pressure on energy grids to integrate renewable energy sources and to manage demand peaks.

What if cars were part of the solution, not the problem

On average, private cars in industrialized countries are driven approximately one hour per day only, leaving them parked for about 95% of the time. V2G plans to turn this idle time into an advantage by using EV’s on-board battery modules as buffer storage. From this storage, they can feed electricity back into the grid in times of peak demand. Once rolled out broadly, EVs would not just consume power, but would contribute to grid stability (by reducing the probability of disruption from load variations), to more renewable integration, energy storage and resilience. In addition to grid operators, vehicle owners would also benefit by charging their EVs at off-peak times and selling electricity back to the grid at peak times when prices are higher.

Vehicle-to-home (V2H) or vehicle-to-building (V2B) are concepts in which the vehicle, photovoltaic panels on the roof, and the building are connected and in which the EV fulfills the role of electricity storage for the household: EVs can generally store more than an average home’s daily energy demand.

V2G: Plenty of potential for electrification, grid stability and energy storage …

In early 2025, the National Development and Reform Commission in China and the Chinese energy authority have announced the launch of 30 V2G pilot projects in nine cities, highlighting the potential of EVs for energy storage in real life conditions. In Europe, the Fraunhofer Institutes ISI and ISE for Transport & Environment claim that EVs could emerge as “batteries on wheels” and “virtual power plants” which have the “potential to revolutionize our energy system”. According to their study, bidirectional charging could save EU energy systems EUR 22bn by 2040 due to a reduction of generation capacity, curtailments and fuel consumption. Total savings between 2030 and 2040 could amount to EUR 175.45bn, which almost equals the entire EU budget in 2023.[2]

As a result, EVs could contribute more than 4% of Europe’s electricity demand by 2030 (equaling the energy supply of 30 million households), more than 10% by 2040[3] and could enable an additional 430 gigawatt of solar power capacity, nearly doubling the current EU capacity. The need for stationary battery storage could be cut by a whopping 92% in 2040, while backup power plant capacity could also be reduced significantly.[4]

... yet significant challenges persist

While the potential of V2G is big, so are the regulatory, legal, liability and technical challenges related to it. First off, it needs a high number of electric vehicles with bidirectional charging as well as public and private connection points to the grid. Secondly, obstacles such as lack of standardization and interoperability, with different communication protocols and inverter specifications, need to be overcome. In addition and as of yet, there are insufficient grid incentives and compensation models for grid operators and EV owners.

V2G is also considered particularly challenging since the vehicle owner would leave central control functions of the charging and discharging to the grid operator. This would affect the manufacturer’s warranty conditions, further aggregating battery degradation concerns. Since rechargeable batteries have a finite number of charging and discharging cycles – could V2G lead to accelerated battery wear and less value? That challenge is to be addressed by the joint teams of battery manufacturers, OEMs, grid operators and government.

Even though EU legislation is supporting bi-directional charging with the Alternative Fuels Infrastructure Regulation (AFIR) and updates to the Renewable Energy Directive (RED II/III), which includes mandates for interoperability and smart charging capability, and more bidirectional-capable vehicles are entering the market (in accordance to ISO15118-20), full-scale implementation is pending.

V2G-ready contactors: Engineering challenges in bidirectional power systems

V2G challenges, however, do not stop at the regulatory level but also extend to the system components of both EVs and charging stations. Firstly, DC safety and isolation requirements are very strict. V2G-ready contactors must be engineered for symmetrical arc handling and consistent performance regardless of current direction. Isolation must be maintained under all fault conditions, including routine switchings and overcurrent conditions. One of the coming trends is integration with control and monitoring systems at the vehicle and charging station, so smart contactors become particularly valuable.

Secondly, round-trip efficiency, the efficiency of the entire charging and discharging cycle, is estimated between 80 and 90%, depending on factors such as battery health, temperature, charge rate and charge state but also on system components other than the battery. These losses, however, are crucial for evaluating the economic viability of vehicle-to-grid.[5] Advanced bi-directional contactors such as Schaltbau’s C303, C305 and C330, C310 and C320, feature silver alloy contact pills of the right size and the proper contact force which significantly reduce contact warming (measuring 2 to 3 times lower than competitors). Because of their superior thermal management capabilities, they reduce heat dissipation, hence protecting components from excessive wear and maintaining an efficient energy transfer.

They also feature a compact, open-isolation concept which prevents rupture even under the heaviest failure conditions and heavy short-circuit events. Schaltbau contactors with an integrated mirror contact function for switch-state monitoring also ensure a high standard of safety for the entire system.

EVs: More than decarbonization of transport

Electric vehicles show the transport sector a clear way to decarbonization, but there are certainly more benefits to be realized if the regulatory, policy and technical challenges of V2G are mastered. As a solution provider for advanced bidirectional charging challenges, Schaltbau’s advanced contactors contribute to system-level system and reliability in complex bidirectional environments.

[1] Statista, Global energy storage - statistics & facts, February 27, 2025.

[2] Fraunhofer ISE & Fraunhofer ISI on behalf of Transport & Environment, Batteries on wheels: the untapped potential of EVs, Oct 30, 2024.

[3] EY & Eurelectric, Plugging into potential: unleashing the untapped flexibility of EVs, 2025.

[4] Fraunhofer ISE & Fraunhofer ISI on behalf of Transport & Environment, Batteries on wheels: the untapped potential of EVs, Oct 30, 2024.

[5] Joint Research Centre of the European Commission Technical Report, Vehicle-to-Grid and/or Vehicle-to-Home Round-Trip Efficiency, 2021.

Connectors connect everything from a soldier’s helmet to vehicle-mounted control stations. And as platforms get smaller, lighter, and more mobile, connectors are being pushed to deliver more performance in less space—without compromising on reliability.

Take modern combat helmets. They're no longer just for protection—they're mobile control hubs. They might integrate communications, data links, situational displays, and sensors. All of it needs to be securely connected. And those connectors can't afford to be the weakest link.

Gone are the days of oversized, overbuilt components. Today, every gram and millimeter matters.

Miniaturization isn't just a size challenge—it's a performance one. Defense systems operate in environments full of dust, moisture, vibration, and electromagnetic interference. Connectors must withstand all of that, while maintaining signal integrity and mechanical durability.

The industry is rising to the challenge with a wave of innovations that balance size, performance, and durability. Connector designs are becoming increasingly compact while still supporting high-speed data transmission. Advanced electromagnetic shielding—often exceeding 70 dB—is now standard, ensuring protection against interference in complex electronic environments. Sealed couplings rated to IP68, even when mated, offer robust protection against dust and moisture. Additionally, self-cleaning mechanisms with spring loaded contacts are being introduced to ensure long-term reliability in the harshest field conditions.

This isn’t speculative tech—it’s already being designed into systems that are fielded today.

Regulatory compliance has become a front-end design priority. Defense programs now demand full RoHS conformance—no exemptions. That means no hazardous materials like lead or cadmium.

As the line between military and industrial applications continues to blur, global deployments increasingly require connectors that meet both performance and compliance standards from the start.

If your connector design isn’t compliant, you’re not even in the running. Defense engineers today expect more than just ruggedness—they need solutions that are tailored to the mission. This includes finishes that reduce visual signature, such as matte black, non-reflective surfaces; materials engineered to withstand exposure to hydraulic fluids and other harsh chemicals; locking mechanisms that are both secure and easy to operate under pressure; and modular configurations that can be quickly adapted to meet the specific needs of different platforms or use cases.

What used to be a custom luxury is now the standard expectation.

Connectivity as risk management: as defense systems grow more interconnected, high-speed, and mobile, the reliability of every link in the chain becomes critical. The demand for low-latency, high-bandwidth connections is rising—especially with the adoption of AI-enabled systems and advanced sensor suites.

When systems fail in the field, it's often the smallest component that causes the biggest issue. That’s why connectors can’t be an afterthought. They are fundamental to mission risk management, where every signal matters and every failure has consequences. This is why the integrity and reliability of signal transmission are so important.

Our newly launched VG/NF connector series embodies everything today’s defense systems demand—mission-ready performance, environmental responsibility, and full regulatory compliance.

Building on decades of proven reliability, this new generation sets a higher standard. Featuring cutting-edge surface technology and newly developed base materials, our VG/NF connectors deliver:

• Shielding performance over 70 dB to protect against EMC
• Resistance to harsh substances like hydraulic oil, diesel, and chemicals
• Matte black, non-reflective finish ideal for stealth applications
• RoHS compliance with zero exemptions—no cadmium, no lead
• Compliance with the stringent VG96934 “J” standard
• IP68 sealing, even when mated, and self-cleaning pogo pin contacts
• Over 5,000 mating cycles for long-term reliability

These connectors represent more than technical excellence—they reflect our commitment to sustainability and future-ready defense design.

If you're designing equipment for modern defense environments, your connector strategy is no longer just a detail—it’s a decision that impacts performance, safety, and compliance.

It’s not always the flashiest tech that makes the biggest difference. Sometimes, it’s just about getting the connection right—and keeping it that way, no matter what.

Want to see how our VG/NF series can support your next mission? Learn more here.

Built on more than 20 years of engineering excellence, the series embodies the trusted quality of the company’s “Made in Germany” heritage. With advanced shielding technology that is fully RoHS conforming[i] the new 10-pol connector series also meets the demanding VG96934 version "J" specifications for defense-grade reliability.

“In today’s geopolitical climate, the reliability of critical infrastructure components has taken on renewed importance—especially in defense and national security applications,” said Helmut Pusch, CEO, Schaltbau Group GmbH. “We’ve been trusted to supply critical infrastructure for decades. This latest generation of connectors reflects our commitment to reliable, regulation-ready technology that delivers peace of mind in the field—no matter the conditions.”

Built for harsh and high-risk environments, the connectors feature shock- and vibration-resistant construction, gold-plated, self-cleaning pogo pin contacts, and 70+ dB shielding to maintain consistent signal quality and eliminate costly downtime. A compact design and matte black, non-reflective finish offer discreet performance, while IP68 sealing (both mated and unmated) protects against water, dust, and chemicals—even under pressure.

Highly configurable and adaptable, VG96934 Version J connectors support evolving mission requirements without major redesign nor new product approval, reducing maintenance effort and extending the lifecycle of critical systems. With over 5,000 mating cycles, they are built to perform reliably over the long term. A RoHs-compliant 7-pin variant is also available, which complies with the defense equipment standard VG95351.

Whether for defense-grade communication, advanced automation, or rugged transportation systems, both Eddicy’s connector series deliver connections customers can count on in critical systems across industries.

To learn more about the new VG96934 Version J connectors, visit here.

[i] RoHS Richtlinie 2011/65/EU + Richtlinie (EU) 2015/863

When Warren Buffett stated, "Price is what you pay, value is what you get," he could have been speaking directly to today's engineering and procurement experts tasked with selecting critical electromechanical components for industrial, energy storage and e-mobility applications. Their challenge is to decide based on cost, quality, service life and sustainability, all at the same time.

Without doubt, ESG requirements have tightened, and global warming is advancing faster than we previously imagined. However, cost pressure, customer expectations, competition, and a host of macroeconomic challenges are also intensifying, making it harder to secure long-term success. So how do you decide?

Clearly, for the transition to a climate-neutral economy to occur, clean technology needs to have a lower total cost of ownership (TCO) to stand a chance of being adopted over traditional components. Battery and solar technology are a case in point where dwindling prices allow business decisions that are fully aligned with environmental targets.

Total cost of ownership in electrical component selection

In industrial automation and electrification, total cost of ownership has become an essential metric because it calculates not only the purchase price but all costs until the end of an electrical component’s lifetime. This includes operating costs, set-up and ongoing maintenance costs, service-life before replacement and more.

This more holistic approach transforms component selection from a narrow financial calculation into a strategic decision. Indeed, according to research from Deloitte, procurement leaders named “addressing total lifecycle/ownership costs” to be among their top five strategies to deliver value to their respective enterprises.[1] At the same time, procurement departments are often stretched thin: Calculating each single cost component in a TCO analysis may be unrealistic and overdone.

The hidden cost of energy losses

Inefficiencies in electromechanical components are a challenge in energy, e-mobility and industrial systems. Seemingly modest components controlling the power flow, such as contactors, can have very different effects on operational costs. Schaltbau and Eddicy customers and their (end) customers buy, store and/or sell energy via their applications – be it electric vehicles, charging stations, energy storage solutions or test benches – obviously, they don’t want to lose it.

How can a contactor contribute to energy efficiency? Resistance is the parameter where energy loss within the contactor can occur and which can be affected. To do this, contactors need to optimize their coil consumption and to keep their contact resistance as low as possible. Schaltbau’s Eddicy contactors provide best-in-class efficiency because of their massive AgSno2 contact tips (versus pure copper or thin-film plated contact tips) and electronic control for the optimal power consumption both at pull in and holding. As a result, contact warming is two- to three times lower than comparison competitors.

Less energy loss in the coil circuit and at the contact tips translates into reduced (energy) costs, better ranges and optimized thermal management/cooling for e-vehicles and e-charging, and lower total operational costs for energy storage systems. While some applications may only need two contactors, most charging stations require at least a half dozen. And energy storage systems easily contain dozens or hundreds of contactors which are in operation 24/7. Even small differences in energy efficiency can add up quickly.

TCO calculator: Show don’t tell

Eddicy’s direct current (DC) contactors have a unique selling point: As their coil consumption and power losses are much lower compared to competition, the (end) customer will save energy and costs in their system over the full product lifecycle. This benefit is not just a promise, but a proven result.

Schaltbau’s TCO calculator compares the total cost of contactor power loss for your entire application using Schaltbau contactors vs. competitor products. The calculation inputs the respective contactors’ voltages (V), thermal current (A), contact resistance (mΩ) and coil power loss (W). It then calculates the power loss per pole, namely, the energy loss via contact resistance and coil consumption, the total energy loss (kWh/year) as well as the total cost of contactor power loss for the entire system. The calculation can be adjusted to the respective energy price a customer pays, the number of contactors to be installed in their systems, the number of hours per day the system is running and the expected contactor lifetime before replacement.

Electric charging station power loss calculation

Indeed, minimizing power losses in your contactor add up quickly (s. Figure 1): A charging station, for instance, which deploys 6 contactors (two contactors per gun and two contactors for the switching matrix), will lose about EUR 1,014 in contactor power losses for the charging station over 15 years of operation with the C303 Ecosave, but a whopping EUR 2,759 or EUR 2,171 with competitor contactors, respectively.
 

Energy storage system power loss calculation

The cost difference widens significantly in higher current applications that run 24/7, such as energy storage systems (s. Figure 2). In a large system with 20 contactors, the total contactor power loss for the entire system over 15 years of operation is EUR 9,853 with an Eddicy C310 contactor but rakes up to EUR 22,069 and EUR 17,370 with competitor contactors. Hence, making a purchase decision based purely on the price of the component might lead to unnecessarily high operational costs down the road.

Energy efficiency: “First fuel” for the energy transition

As the International Energy Agency points out, energy efficiency is the “first fuel” in the energy transition as it provides some of the quickest and most cost-effective CO2 mitigation options while lowering one’s energy bill. By accounting for energy efficiency, operational reliability, and service longevity, TCO helps to illuminate how premium components deliver twin imperatives: substantial cost savings over the product lifecycle and advancing sustainability objectives. For this reason, economic optimization and sustainability become complementary forces rather than competing priorities in the journey toward electrification and decarbonization.

Interested in your personalized contactor TCO analysis? Download our TCO calculator here to see the potential savings in your application – or reach out for a personalized analysis from our experts.
 

[1] Deloitte, 2023 Global Chief Procurement Officer (CPO) Survey. Orchestrators of Value, p.8.

Schaltbau, a global leader in direct current (DC) technologies, is proud to support Swissloop, a student-led pioneering organization dedicated to the development of hyperloop transportation technologies. With this sponsorship, Schaltbau underscores its commitment to next-generation mobility solutions and the development of vital innovative engineering talent.

"Achieving the All Electric Society requires commitment and a pioneering spirit. Projects like Swissloop are an important building block in this regard," said Helmut Pusch, CEO, Schaltbau GmbH Group. "By directly supporting passionate, talented engineers of the future, we are actively shaping the evolution of transportation towards greater sustainability, efficiency, and speed."

Swissloop is developing cutting-edge prototypes, called "pods," that are designed to revolutionize transportation—with speeds faster than airplanes and efficiency surpassing conventional rail. The partnership will support Swissloop students in the design, manufacture, and rigorous testing of their Hyperloop pod, enhancing their skills in printed circuit board design, CAD modeling, structural analysis, electromagnetics, and more. Swissloop will showcase its latest innovations at the prestigious European Hyperloop Week from July 14-20, 2025, an international competition where teams from all over the world compete, collaborate, and share knowledge.

Schaltbau's sponsorship underscores its leadership in sustainable and advanced transportation solutions, playing a vital role in driving forward the transformative vision of Hyperloop technology.

“Battery electric and hybrid propulsion are no longer technology visions — they’re already delivering real benefits today. We know, for instance, that electric trains can emit up to 65% less CO₂ in service compared to diesel counterparts, depending on the local electricity mix,” said Helmut Pusch, CEO of Schaltbau Group. “That’s a transformative efficiency gain, and it’s exactly what Schaltbau’s contactors are enabling across modern rail systems.”

Rooted in technologies proven across demanding rail applications for decades, Schaltbau’s CP and CF series of high-power contactors deliver robust performance in both propulsion and battery-train contexts. Featuring advanced arc-extinguishing chambers, modular configurations, and bi-directional switching, they are now available in new variants.

The CP Series, ranging from 600 A to 2,000 A (new variants rated at 800 A, 1,000 A, and 1,500 A), are designed for seamless heavy load operation, minimal energy losses and maximum uptime and thereforekey to reducing total cost of ownership (TCO) in demanding rail applications. At the same time, the new modular, multipole CF contactor series configurable up to 400 A with AC/DC switching capability isideal for integrating traction units and onboard energy storage. Both solutions significantly enhance the performance and safety of battery-train architectures by effectively managing high-current conditions during battery connection and disconnection cycles.

In addition to its contactor portfolio, Schaltbau will also showcase further product highlights including connectors, precision-engineered snap-action switches, and electrics for rolling stock including driver desks and displays of its daughter company, SPII.

"With the global EV market set to grow by over 20% annually over the next decade, high-voltage DC technology is more crucial than ever in driving ultra-fast megawatt charging, improving energy efficiency in commercial vehicles and AGVs, and unlocking the full potential of electrification in heavy-duty applications," said Helmut Pusch, CEO of Schaltbau GmbH Group. "Innovations like our new C803 and C830 megawatt charging contactors are accelerating the transition to sustainable transportation. We look forward to showcasing them at this year’s iVT Expo in Cologne, where the future of e-mobility will take shape."

In addition to its high-voltage off-road contactors, Schaltbau will present its expansive Eddicy portfolio of low-voltage contactors, for intralogistics.  Highlights include the new C303 LV, specially developed for low-voltage applications as well as the expanded C110B series, a single-pole, bidirectional DC contactor designed for battery-powered applications, with a 1,200 A breaking capacity and a compact, sealed design for enhanced durability in harsh environments—now available in a 400 A version.

Schaltbau will also showcase its comprehensive range of Eddicy connectors tailored for both high- and low-voltage applications. The HV series supports up to 1,000 V DC and 470 A, featuring IP69K protection, high mating cycle durability, and one-handed operation—ideal for demanding environments. For low-voltage needs, the LV series offers safe, reliable power transfer up to 500 A, tailored for vehicles and systems in intralogistics, public transport, and light electric mobility. Both series are designed for harsh conditions, ensuring efficient and secure connectivity across a wide range of use cases, from battery systems and drivetrains to precision low-voltage interfaces.

Visitors will experience firsthand how Eddicy is driving the future of electrification across a wide range of applications. From EV charging infrastructure and commercial vehicles to intralogistics and heavy-duty equipment, Eddicy solutions are engineered to meet the highest standards of performance, safety, and efficiency.

Discover Eddicy solutions for off-road e-mobility and intralogistics at iVT Expo 2025: 

June 11-12, 2025, Köln Messe, Hall 4.1, Booth 10015
For more information about the event, please visit us here: https://schaltbau.com/en/trade-shows/ivt/

The world has never been more connected. Goods and people are moving further and faster than ever before, with no end in sight. Passenger transport and global freight demand are each expected to triple until 2050, according to projections of the International Transport Forum at the OECD.

The state of electrification for heavy-duty commercial vehicles

When it comes to electrification, not all heavy-duty commercial vehicles are created equal. Buses, and city buses in particular, have become electric much faster, thanks to their relatively fixed routes, lower travel distances and ability to depot-charge. Sales of electric buses are far ahead of other heavy-duty vehicle segments in all geographies. In the European Union, battery-electric vehicles reached a 43% share among city buses in 2023.[3] The same trend is applicable to light electric commercial trucks that are mainly used within cities, i.e. in zero emissions or “green” zones for freight.

However, when it comes to heavy-duty vehicles, diesel trucks still made up for more than 95% of sales in the EU in 2021.[4] Electric truck sales increased almost threefold in 2023 in Europe, but still accounted for less than 2% of total sales. In the United States, the number tripled as well but accounted for a mere 0.1% of total truck sales. The notable exception is China, which accounted for 70% of global electric truck sales.[5]

On a global level, sales of battery-electric HDVs for the first time surpassed the sales level of electric buses. This indicates that electrification of HDVs is accelerating, largely because of technological advancements in e-truck and charging technology as well as more ambitious CO2-reduction targets for the sector in several geographies. In the EU, regulation now sets the path for truck OEMs to reduce their new fleet emissions by up to 45% by 2030 and by at least 90% by 2040.

Key enabler, key bottleneck: Charging

According to a prognosis by PwC, more than 20% of transportation will be electrified by 2030 – driven by the diffusion of heavy-duty vehicles and urban buses.[6] But how will this steep growth come about in only a few years? Largely because battery-electric powertrains could achieve total cost of ownership parity in many heavy-duty vehicle applications this decade, including long-haul trucks: “Even for the very challenging long-haul cross-border truck applications, battery electric technology can provide the most cost-effective solution before 2030, assuming the availability of a high-power MW public charging infrastructure in Europe.”[7]

In an industry where time equals money, megawatt charging is a key enabler for the electrification of heavy-duty transport. Imagine a highway rest stop where electric, emission-free heavy-duty trucks pull in silently not for a 70-minute recharge that is common today even with DC fast-charging (e.g. 350 kWh), but for a swift 15-20 minute “pump-and-go” refueling, akin to diesel stops today. This is the promise of megawatt charging. Yet, achieving such “diesel-like” turnaround and uptime for electric commercial fleets hinges on overcoming formidable technical and infrastructure challenges.

Many of the infrastructure challenges yet to be overcome require close cooperation of policymakers, grid operators, charging manufacturers and logistic fleet operators – including the limited availability of megawatt chargers along public corridors, investment in grid-connected high-power hubs, grid limitations and power availability at highways rest stops, investments in depot charging infrastructure, managing more route planning complexity, and more.

Gearing up for the megawatt charging standards (MCS) levels 2 and 3, however, also poses fundamental challenges for the electromechanical components used in batteries and chargers to safeguard performance, safety and system reliability. While MCS level 2 targets up to 1.5 MW (1.500 A at up to 1,000V), MCS level 3 aims for up to 3 MW or more with voltage up to 3,000 A. This power boost drastically reduces recharging times even for large battery packs. In essence, MCS level 3 will provide the industrial-grade readiness that will scale the electrification of heavy freight transport on highways, not just in more controlled and predictable depot environments. If charging standards, grid updates, and the vehicle-side technology align, level 3 charging could roll out commercially before the end of this decade.

Against the backdrop of global climate targets, particularly the EU’s commitment to reduce emissions by at least 55% by 2030 and reaching climate neutrality by 2050, megawatt charging isn’t just about convenience—it’s necessity. To meet the -1.5°C goal, the rapid decarbonization of freight transport must accelerate now. That means megawatt charging must advance as a present-day requirement, and not a future ambition. Charging and vehicle manufacturers need to urgently align their roadmaps and begin planning their next-generation products around MCS level 2 and 3 standards to meet the pressing climate and regulatory timelines.

How to overcome thermal challenges in megawatt charging

Because of the extremely high currents at play with MCS levels 2 and 3, thermal management is one of the most critical hurdles that can threaten performance, reliability and safety of freight, vehicle and driver. The higher the current, the faster the charge, but also the more heat is generated when electricity is sent through cables, connectors, contactors and into the battery. At megawatt charging levels, between 1,000 to 3,000 A are pushed, which is 30 to 50 times more than what a typical home EV charger delivers.

Heat is the main byproduct of high-speed charging, and if it’s not carefully managed, it poses safety risks since overheated components can melt, short-circuit, or even catch fire. Components also wear out faster when exposed to high heat. And, most importantly, batteries degrade much faster when they are repeatedly charged under hot conditions, which reduces range, lifespan and the residual value of e-trucks, thus putting their TCO at disadvantage with conventional diesel-powered trucks.

Even if heat is managed with liquid cooling that takes away the heat in high-current applications, it still takes a heavy toll on TCO: Power losses grow quadratically with current. Hence, a significant portion of energy needed for the powertrain or the battery evaporates as heat and may necessitate additional cooling which comes with a price tag as well. At the contactor level, it is therefore imperative to minimize contact resistance in high-current applications in order to maintain an efficient energy transfer and to ensure competitive total costs of ownership.

Schaltbau has already introduced a new series of bi-directional contactors designed for stationery and mobile megawatt charging at level 2 and level 3. Its flagship solution C330 reduces contact resistance to as low as 40 µOhm, ensuring best-in-class performance with low contact warming. In contrast, average DC contactors on the market register power losses of over 200 µOhm (equaling a power/heat loss of 450W at 1,500 A).

With two main circuits – one for making and breaking, one for carrying the current to ensure maximum contact protection – the C330 also ensures stable contact resistance and the same thermal performance over long periods of operation. The megawatt charging contactor series reduces power losses in the system, delivering up to 25% of energy cost savings and avoiding the costs associated with extra cooling.

To electrify heavy-duty fleets at scale, OEMs and fleet operators need more than powerful batteries and fast chargers—they need highly efficient, thermally robust, and future-ready components. Megawatt charging is not just a technological advancement; it’s a strategic imperative for achieving climate goals and maintaining competitiveness. The transition to zero-emission transport hinges on infrastructure and vehicle readiness, and both must accelerate now. With smart thermal management and robust components, the path toward sustainable commercial transport is not only viable, but inevitable.

Learn more about our solutions for megawatt charging and how we can support your electrification goals here.

References

[1] International Transport Forum, ITF Transport Outlook 2019.

[2] European Commission, Reducing CO₂ emissions from heavy-duty vehicles, 2023.

[3] International Energy Agency, Trends in heavy electric vehicles – Global EV Outlook 2024.

[4] Basma, Hussein; Rodríguez, Felipe, A total cost of ownership comparison of truck decarbonization pathways in Europe, International Council on Clean Transportation Working Paper 2023-28, November 2023.

[5] International Energy Agency, Trends in heavy electric vehicles – Global EV Outlook 2024.

[6] PwC, Truck Study 2024. The diversification of battery-electric truck platforms will shape the next phase of the eMobility revolution, September 2024.

[7] Basma, Hussein; Rodríguez, Felipe, A total cost of ownership comparison of truck decarbonization pathways in Europe, International Council on Clean Transportation Working Paper 2023-28, November 2023, p. 19

At the heart of Eddicy’s offering are the megawatt contactors, now expanded to meet the rising demand for MCS Level 2 and Level 3 charging systems. The latest innovations feature compact designs tailored to both high-power stationary and mobile applications, ensuring fast, efficient, and safe charging for electric commercial trucks, e-buses, and more.

“Megawatt charging is beginning to move from lab to highway. And we are ready: Our megawatt charging contactors can handle up to 3,000A, which is the kind of power needed to recharge a commercial truck in 15 minutes during a regular driver’s break,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “Our solutions minimize contact resistance, maintain system safety, offer a competitive total cost of ownership and thus enable true long-haul trucking or heavier e-trucks for mining and off-road logistics.”

The new contactors for both stationary (C305 and C330) and mobile (C805 and C830) applications feature a compact, open-isolation design that offers robust protection under extreme conditions. Even during high short-circuit events, the contactors prevent system damage and component failure. The C330, for example, can withstand a short-time current of 15,000A for five milliseconds without contact welding — a critical safety benchmark for high-power systems. The contactors have silver alloy contact pills for industry-leading contact resistance as low as 40 µOhm. The result: greater safety, energy efficiency, and reliability, even under extreme operating conditions.

In addition to the new megawatt charging products, Eddicy presents its compact C303 and C803 contactors engineered to meet the strict space requirements of charging stations and e-mobility platforms. With low contact resistance, these contactors minimize power losses and heat generation, while their robust design extends operational lifespan, reducing the need for frequent replacements and minimizing downtime. These features make the C303 and C803 ideal solutions for demanding e-mobility and fast charging applications, offering significant long-term cost savings up to 25%.

Discover the Eddicy megawatt charging solutions and meet our experts at The Battery Show Europe: June 3-5, 2025, Stuttgart, Hall 9, Booth C86

For more information about the event, visit here.  

Schaltbau, a global leader in direct current (DC) technology, has received the German Innovation Award 2025 in the “Excellence in Business to Business” category for electronic technologies. The accolade celebrates the company’s Eddicy SC503 smart contactor which provides maximum circuit protection coupled with intelligent monitoring and communication functionalities to a variety of industrial, energy and automotive applications, including DC microgrids, energy storage systems, test benches and electronic vehicle charging.

This marks the second consecutive year Schaltbau has won this prestigious award. In 2024, the company was recognized for the NExT Factory, the world’s first DC production facility, which represents a major step towards achieving net-zero industrial energy use. Together, these wins reflect Schaltbau’s unique strength in both innovative product development and system-level contributions to a more sustainable, electrified future.

“We are honored to win this award for the second time in a row. This recognition speaks to our commitment to push the boundaries of direct current technology,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “Developing our intelligent devices to equip DC microgrids and energy storage solutions will help industrial customers enjoy greater energy efficiency, resilience and availability in weakening energy grids, more control over their energy consumption and, above all, lower energy costs and grid fees.”

The SC503 marks a new era for contactor technology due to its enhanced functionality, efficiency and adaptability. It features active voltage and current measurement at the switching element, enabling real-time monitoring, localized decision-making, communication of data to higher-level units and response to system conditions. With a voltage range of 600V to 800V DC and nominal current capacity of up to 300A, the SC503 provides an advanced solution for high-performance applications. By leveraging local decision-making based on real-time data, the SC503 provides benefits in terms of increased productivity, reduced wear and tear, and enhanced energy efficiency.

These advances directly support the vision of an All Electric Society—a future powered by renewable energy and enabled by intelligent, DC-based infrastructure. With products like the SC503 and initiatives like the NExT Factory, Schaltbau continues to demonstrate how electrification can drive both innovation and sustainability.

The German Innovation Award recognizes products, projects and pioneering achievements that sustainably improve life through innovation and progress. Each year, nominees are selected for creating added value in society, the environment or the economy through their innovative processes and ideas.

Note: The SC503 was previously referred to as the Smart Circuit Breaker.

“The race in e-mobility is on and manufacturers strive to bring better, higher-range vehicles into the market with shorter development cycles,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “With electric vehicles operating up to 1,500V and above, and with currents in the kiloampere range, we provide the broadest contactor portfolio as well as highly tailored solutions with sustainable, European-based production to ensure that test benches can handle extreme conditions safely.” 

In demanding test bench applications, contactors play a critical role in switching current, especially direct current. The technical challenge lies in the safe extinguishing of the arc, preventing insulation breakdown, and reliably withstanding thermal currents and short circuit currents during demanding testing conditions. Schaltbau´s Eddicy brand offers a broad portfolio of AC and DC contactors from 40 A to 3,000 A, including customized solutions for highly specialized test setups. Flagship models include the compact C303 (rated at 500 A) and the newly launched C330, which covers up to 3,000 A and can handle short-circuit peaks of 15,000 A for five milliseconds – making it ideal for high-power testing.

Eddicy solutions are engineered for safety, durability, and precision, featuring extremely low contact resistance that reduces energy losses and enables thermal performance without excess cooling – contributing to up to 25% energy cost savings in high-load applications. The compact size of Eddicy contactors also helps optimize space in test environments, while supporting more efficient system integration.

Other key features of Eddicy’s test bench contactors include enhanced safety and improved reliability with high isolation voltage up to 4,800 V, robust uni- and bi-directional current interruption, and auxiliary contacts with normally open, normally closed, or mirror contact functionality, ensuring a reliable feedback loop compliant with IEC 60947-4-1, Annex F. Reinforced contact tips minimizing the risk of contact welding and reducing downtime in test bench environments. Together these attributes make Eddicy contactors a trusted choice for next generation AC and DC testing, where safety and system uptime are paramount.

At the heart of the showcase is the new megawatt charging contactor portfolio, featuring the C305/805 and C330/830 series. These compact, high-performance contactors are designed for both stationary and mobile megawatt charging applications, meeting MCS level 2 and level 3 requirements. The C330 model, capable of handling 3000A in bi-directional applications, has already been nominated for the prestigious "smarter E AWARD 2025", underscoring its innovation and impact on the fast-charging sector.

“Megawatt charging is a game-changer for commercial e-mobility. With this portfolio, we’re enabling ultra-fast charging that matches the pace of a typical driver’s break — without compromising safety or system efficiency,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “With Eddicy, we’re not just innovating — we’re delivering.”

All four new models (C305, C805, C330, C830) feature an open-isolation design, withstand short-circuit currents up to 15,000A for 5ms, and use silver alloy contact pills for industry-leading low contact resistance of just 40 µOhm for the C330/C830 and 50 µOhm for the C305/C805. The result: greater safety, energy efficiency, and reliability, even under extreme operating conditions.

Also showcased at the event will be Eddicy’s smart contactor SC503, a modular DC switching solution that combines intelligent condition monitoring with high-current performance. In a live busbar demonstration at the Rittal booth, visitors can see the SC503 in a real-world setting, highlighting its plug-and-play integration with modern power distribution systems.

With these innovations, Eddicy continues to drive the evolution of energy infrastructure, delivering future-proof solutions for EV charging, battery storage, and intelligent DC power distribution. Visitors can find Eddicy in various tradeshow areas including:

• ees Europe, Stand 476, Hall B2 (Eddicy)
• EM-Power Europe, Stand 310, Hall B5 (Rittal)
• Power2Drive Forum during the session entitled, “Global E-mobility Outlook: Vision Meets Innovation” on May 7^th, 2025, 10:30am, Stand 550, Hall C6

“Megawatt charging represents a milestone in commercial e-mobility. By reducing charging time to the length of a driver’s break, it significantly maximizes both flexibility and efficiency off green transportation,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “With our new contactors, we are delivering the future of charging today, emphasizing our commitment to driving electrification for a sustainable future.”

The new contactors C305 and C805 support the current Megawatt Charging Standard (MCS) level 2 of 1,500A, the C330 and C830 contactors are 3,000A bi-directional contactors designed to enable MCS level 3 high-power DC charging. All four products feature a compact, open-isolation concept which prevents rupture even under the heaviest failure conditions and heavy short-circuit currents, preventing damage to surrounding components. The contactors can withstand a short-time current of up to 15,000A for five milliseconds without the contacts welding, significantly enhancing system safety. With separate contact systems for switching and current carrying, the series stands out for its exceptional longevity.

Furthermore, silver alloy contact pills result in a contact resistance as low as 40 µOhm, ensuring best-in-class performance with low contact warming. An integrated economizer ensures optimal pull-in performance during switch-on and minimizes energy consumption in holding mode. As a result, the megawatt charging contactor series reduces power losses in the system, delivering up to 25% of energy cost savings.

“Power losses grow quadratically with current, so minimizing contact resistance in high-current applications is crucial for maintaining an efficient energy transfer and ensuring competitive total costs of ownership", said Schaltbau CEO Pusch. “That’s why our new Eddicy contactors are ideal for high-current applications like fast charging, as well as other energy and e-mobility applications such as battery storage systems and test benches.”

The C805 and C830 contactors for mobile applications will be unveiled today at the ACT Expo in Anaheim, California. The C305 and C330 contactors will be debuted at smarter E Europe in Germany where the C330 has already been nominated for the smarter E AWARD, which honors companies shaping the future of energy and mobility.

Learn more about C305/C805 & C330/830 contactors here