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.

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. 

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.

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.

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.

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

From the first wire-guided truck in the early 1950s onwards, autonomous-guided vehicles (AGVs) that independently transport goods and products from one place to another, along with modern automated mobile robots (AMRs), have been changing how intralogistics solutions of today provide efficiency, flexibility and safety with minimal noise and zero emissions. Now, machine learning, sensor technology and vision systems are making it possible to fully automate many existing processes with AGVs that have traditionally been manual or semi-automated.

Intralogistics automation grows rapidly

As a result, the automation market is booming, with warehouse automation accelerating with a 10% growth rate per year, according to McKinsey.¹  In the quest to boost their competitiveness and throughput, companies are planning to increase their investment in automation significantly over the next five years, reaching 25% of capital spending on average. In logistics and fulfillment, automation is expected to account for more than a third of capital spending, the largest fraction of any sector.²

According to BCG, the business case for doing so is stronger than ever: By implementing advanced logistics solutions, manufacturers can reduce in-plant logistics and warehousing costs by approximately 30%.³ AGVs, in particular, promise manufacturers to tackle the most pressing supply chain problems: skilled labor shortages, improving fulfillment quality and safety, maximizing space utilization and increasing throughput.

Three AGV performance trends to watch

To stay ahead in the automation race, businesses are focusing on innovations that enhance performance, energy efficiency, and safety. While artificial intelligence, machine learning, sensor technology and advancements in computer vision are enabling AGVs and AMRs to become smarter, faster, more flexible and self-organizing, lower energy costs, greater efficiency and safety in intralogistics rest on innovative electromechanical components such as contactors and connectors.

As a company specializing in high-performance direct current switching, connecting and charging, Schaltbau is helping to enable three key developments for the next generation of AGVs, AMRs, and electrified intralogistics:

48V and high-voltage technologies for AGVs: More and more manufacturers of AGVs transition to 48V and are aiming for 80V or even 120V systems to reduce energy losses and improve performance. Higher-voltage systems allow AGVs to transport heavier and bulkier loads or to operate at higher speeds without significantly increasing system weight. Additionally, at 48V and higher, batteries waste less energy as heat, providing longer operation times and faster recharging – critical for AGV uptime. They also charge faster, especially when paired with high-power charging infrastructure.

However, the higher the voltage, insulation, connectors and safety relays need to meet higher demands to guarantee the high safety standards required. Reliable DC contactors and arc suppression also becomes more critical to ensure reliable power control and effective fault protection.

Fully integrated DC microgrids for warehouse energy efficiency:

While industrial automation significantly reduces personnel costs, other cost factors enter the spotlight in the quest for more efficiency. One key trend is the integration of high-voltage AGVs with DC microgrids, where power (i.e. from renewable sources, such as solar power and/or local battery storage) can be distributed with minimal conversion losses. This reduces inefficiencies that normally occur when switching between alternate current (AC) and DC and can also improve the overall sustainability in the manufacturing process.

However, to ensure safety, these systems need extra protection, such as bidirectional switching components for energy regeneration or pre-charge circuits to avoid inrush currents damaging electronics. Schaltbau connectors such as the LV connector range, further facilitate the connection of sensors, meters and control devices as well as enable the connection of power sources and energy storage devices to the DC bus.

Fast- and vehicle-to-grid charging: Improvements in battery technology are increasing uptime and have accelerated recharging compared with batteries that were available a few years ago. Wireless charging or automated fast-charging systems ensure uninterrupted operation. Bi-directional charging technology also allows AGVs and AMRs to act as energy storage during idle times, contributing to more grid stability and resilience.

High-current charging connectors, such as the Eddicy LV connector range connect electric AGVs, their batteries, and chargers, allowing for fast charging cycles and reduced downtimes. These connectors safely handle high capacities from160 up to 500 amps with minimal self-heating, extremely low contact resistance and noticeably reduced contact forces for a significantly longer service life.

Maximizing efficiency, cutting costs, and ensuring sustainability are no longer optional in a highly competitive intralogistics and manufacturing landscape. AGVs and AMRs powered by high-voltage systems, DC microgrids, and advanced charging solutions are one crucial way to unlock these benefits. Companies that embrace these innovations will not only improve their bottom line but also gain a competitive edge in an increasingly automated and electrified world.
 

References

1. McKinsey, Getting warehouse automation right, 2023.

2. Ibid.

3. Boston Consulting Group, Advanced logistics in the factory of the future, 2022.

From an early age, we learn the importance of making informed decisions, whether as private consumers or when making B2B decisions in our professional lives. Whether we prefer customer testimonials, independent test research, certification or product reviews, we all want to be sure that what we see is what we get.

Suppliers are responsible (and liable) for their products. Particularly in industries where failures can have severe consequences, the rigorous testing of products is not only a technical necessity but a legal requirement to ensure compliance with safety and quality regulations.

The global push for electrification and the increase in moving and stationary battery systems is transforming entire industries, from automotive to energy and industrial automation. As companies innovate and develop new electrified solutions, rigorous testing both in development test benches and end-of-line testing becomes critical in ensuring performance, safety, reliability and regulatory compliance.

The role of test benches in electrification

High voltages, high frequencies, thermal management under challenging current profiles, and possible failure behavior evaluation – all part of the unique engineering challenges electrification introduces – necessitate precise validation and testing of electrical components, power electronics, and entire systems under real-world conditions before deployment. Hence, engineers require adaptable, modular set-ups capable of handling increasing power levels: With electric vehicles and grid storage systems operating at voltages up to 1,500V and above and currents in the kiloampere range, test benches must handle extreme conditions safely.

Test benches, systems to test the function and defined parameters of a device under test (DUT), require powerful contactors and relays to connect the different measurement instruments, power supplies and loads as well as to switch-off of the complete system in case of an emergency. For e-mobility, battery and many other energy applications, the challenge lies in safe extinguishing of the arc, insulation breakdown, and reliably withstanding thermal currents and short circuit currents during high-power testing.

What makes a test bench contactor different?

So, why would your everyday contactor not do it in a test bench to ensure safe power handling? Because they need to follow extraordinary safety standards and have a number of special requirements. Firstly, test equipment needs to be very robust since it is typically difficult to maintain. Understandably, customers prefer electromechanical components that they install once and then never have to think about again.  High short-circuit withstand capacity to avoid “stuck-on” contactors with welded contacts is mandatory as well as a mirror contact feedback according to IEC 60947-4-1. Contactors should be ready to serve a wide current range as well as voltages sometimes than it’s typical in “classic” industry applications. And, above all, test bench contactors need to ensure reliable control of the test samples as well as the safety of the operating personnel and the long-term availability of the test system itself in the event of a fault.

Schaltbau customers rely on our wide range of contactors for a variety of energy and e-mobility applications. Key features of those contactors include their very low contact resistance, leading to low heat dissipation and high thermal currents, excellent isolation voltage up to 4,800 V as well as auxiliary contacts with normally-open and normally-closed functionality or mirror contacts functionality for a safe feedback loop according to IEC 60947-4-1, Annex F. In addition, their high bi-directional current interruption capability makes them particularly suited to evaluate both charging and discharging cycles or energy simulations with connection to a grid. Their non-encapsulated arc chambers provide for a robust design, their sturdy contact-tips makes the probability of the contacts welding low.

Safe and reliable switching for test benches with Eddicy

Our portfolio of Eddicy contactors is designed to deliver exceptional performance and safety across a wide range of applications in e-mobility and energy testing. With a variety of series, such as the CP, 320, 310, 300, C303 and more, we provide versatile solutions to meet both standard and highly specialized requirements.

From high currents to high voltages, our contactors are engineered to handle everything from 10 to 2000A and 24V to 3000V, covering both AC and DC loads. Each series is built with robust features to ensure long-lasting reliability, high efficiency, and exceptional performance even under the most demanding conditions. Our products can be customized to fit any need, whether it's for specialized testing, custom solutions for extra-high voltages, or even addressing unique safety and mechanical challenges. No request is too complex or "off-the-wall" for us.

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

Today, the mining industry, estimated to be responsible for between two and three percent of global CO2 emissions, plays a particular role in the transition to a net-zero economy which harnesses the benefits of (renewable energy) electrification. Seen as one of the most energy-intensive industries, the sector will likely need to reduce at least 85% of its emissions by 2050, according to McKinsey[2], and is considered to be challenging to decarbonize. Downstream consumers of metals, investors and governments alike, however, expect the industry to deliver against its sustainability (and electrification) goals.

Mining: Powering the energy transition

On the other hand, a productive mining industry that is not only sustaining but significantly increasing its output is critical for a carbon-neutral future. Cellphones, batteries, charging infrastructure, wind turbines and more all depend on mined ores. Lithium production, key component of modern battery technology, for instance, is expected to increase at a compound annual growth rate of almost 14% until the end of this decade, according to GlobalData’s commodity production forecast, and may not even be able to keep up with increasing demand.[3]

As a result, mining companies are tackling the double challenge of decarbonizing their operations while maintaining their productivity head-on. Direct current technology and advanced electrical components play a key role, regardless of the strategies mining companies deploy to minimize their Scope 1 (resulting directly from their operations) or Scope 2 (resulting from the energy being purchased or produced by mining companies) emissions. Since it is typically faster and more cost-effective, most mining companies currently tend to focus on Scope 2 in the short-term and have signed power purchase agreements (PPAs) with renewable energy providers or are beginning to install wind and solar farms and the respective DC grid infrastructure directly on-site.

However, the long-term sustainability goals of most mining companies require significant reductions in both Scope 1 and 2 emissions, often with parallel strategies to address each. As a result, more and more electrification technologies for heavy-duty equipment have become viable, requiring advanced electromechanical components to fulfill the specific requirements of open-pit and underground mining.

Benefits of mining electrification

Original equipment manufacturers are starting to offer electric haulage trucks, underground electric vehicles (which eliminate the need for exhaustive ventilation systems), transport and systems and auxiliary machinery due to the advancements in battery energy density, charging speeds and battery longevity. Since charging infrastructure for electric or hybrid-electric hauling trucks is also advancing, mining companies are increasingly tapping into the benefits of electrified equipment, such as lower maintenance costs and operational improvements such as steeper ram designs, lower stripping ratios and less frequent breakdowns. According to McKinsey, a fully electrified mine with renewable power sources could also have a 60 to 80% lower carbon-footprint (avoiding carbon taxes and/or green-product premiums) and less air pollution below and above the ground.[4]

Additionally, operational expenditure gains are significant: Electrification could reduce energy costs by as much as 40 to 70% and reduce maintenance costs for mobile equipment by approximately 30%.[5] Recent IDTechEx analysis highlights that a single, 150-tonne diesel haul truck, for instance, will require over USD 850,000 per year in fuel, and electrification could save over USD 5.5 million in energy alone over the vehicle’s lifespan. Consequently, the electric mining market is predicted to boom: It is expected to stand at more than USD 23bn by 2044, increasing at a 32% compound annual growth rate.[6]

“If you can’t stand the heat, …”

Electromechanical components used in electric off road mining fleets must provide performance, reliability and safety features literally “off the beaten track”. Open-pit and underground mining require equipment systems handling high voltages and currents and can operate in extreme environmental conditions at the same time – from dusty and dirty environments, providing high shock and vibration resistance and tolerating temperatures ranging from -50 to +50 degrees Celsius. Likewise, safety is paramount in mining: Contactors with arc-quenching capabilities prevent electrical faults, reducing the risk of fires and equipment damage.

The Eddicy CP contactor series for electric mining trucks as well as the C320 contactors for other surface- and underground mining equipment deliver proven robustness and high safety, even in failure conditions. They switch and protect the high voltage circuits required by mining equipment, ensuring uninterrupted operations. The direct current arc-handling is done exclusively by permanent-magnetic blowout. This patented technology ensures fully bi-directional breaking capability, meaning that loads can be switched regardless of whether the equipment is charging or discharging.

Apart from safety, operational availability is a key metric for mining operators: In light of the significant (financial) implications of truck downtime, operators strive for operational availability of 90 percent and higher. By enabling the toolless inspection of the main contact tips as well as the toolless replacement of the arc chamber, the CP contactor series already contributes to achieving high availability goals by longer up-times and less replacements. In addition, the series is ready to meet the requirements of the upcoming Megawatt Charging System (MCS) developed for large battery electric vehicles, namely, compatibility with up to 1,250 volts and 3,000 amps. Last but not least, by reducing dimensions and weight and because of its modular design, the high-power CP contactors allow for various configurations, catering to a wide range of applications within the mining sector.

Sophisticated energy management a prerequisite for a sustainable mining future

Electrifying the mining industry will be no easy feat. Technological limitations, high investments, and logistical complexities especially in remote mining areas still pose barriers to electrification. Moving away from diesel to (renewable) energy will require a sophisticated energy management at mines to fulfill the surged need for electricity (and rapid charging): Calculations have shown that a sample open-pit iron ore mine which replaces its 27 diesel haul trucks as well as corresponding loading and auxiliary equipment with electric powered versions could see its electricity demand double.[7]

Mining operations investing into direct current technology, such as upgraded electric-grid connections, microgrids combining renewables with battery storage to achieve off-grid power, (megawatt) charging infrastructure, while introducing electric haul trucks and auxiliary equipment, will be able to control their costs and reduce their carbon footprint while maintaining the productivity levels necessary for the global energy transition towards carbon-neutrality. 

 

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

_REFERENCES

_{[1] CEEC International: Coalition for Minerals Efficiency, Mining Energy Consumption 2021, MINING ENERGY CONSUMPTION 2021 - CEEC (Coalition for Eco Efficient Comminution)}

_{[2] McKinsey, Climate risk and decarbonization: What every mining CEO needs to know, 2020.}

_{[3] Mine, “2024 in data: the trends that shaped the mining industry”, Issue 148, 2025.}

_{[4] McKinsey, Mining electrification could double their electricity demand, 2023.}

_{[5] Ibid.}

_{[6] State of Play, Powering the Future: The Electrification Evolution in Mining, 2024.}

_{[7] McKinsey, Mining electrification could double their electricity demand, 2023.}

Governments, industries, and consumers are increasingly adopting renewable energy sources such as wind and solar. However, the intermittent nature of these sources, where energy generation fluctuates based on weather conditions, presents significant challenges for grid operators. ESS help mitigate these challenges by storing excess energy generated during peak production and releasing it when demand outpaces supply. As demand increases, ESS are becoming integral to energy management. But with this growth comes the need for systems capable of handling larger energy capacities, scaling effectively, and ensuring safety during operation—requirements that demand the highest standards of performance and reliability from every ESS component, including the contactor.

Contactor Technology: Essential to ESS Operation 

Contactor technology is critical in ESS and contribute to overall safety and efficiency in many ways. They manage the flow of power between the grid and storage units by connecting and disconnecting strings and inverters as needed. In the OFF position, the contactor ensures safety by reliably galvanic isolating high-voltage circuits. This prevents electrical hazards to personnel and protects equipment from damage. In the ON position with extremely low ohmic resistance, the contactor efficiently handles high currents, ensuring smooth and reliable operation. In addition to these tasks, contactors provide fault protection by isolating faulty components during overcurrent, preventing damage and maintaining system safety. 

To ensure long-term reliability, modern contactors are built with durability in mind. They use high-performing materials like silver-tin-oxide alloys to avoid contact-welding under system failure conditions and improve the Mean Time Between Failures (MTBF), minimizing downtime and maintenance while optimizing ESS performance. 

Modern contactors are engineered to meet the increasing demands of energy storage systems. Below are the key features that ensure optimal performance and reliability in high-power applications:

1. High Current and Voltage Capacity

Modern contactors are designed to handle substantial current and voltage loads, making them crucial for large-scale ESS applications. The C303 contactor, for example, is tailored for high-performance ESS, managing DC power with a maximum switching voltage of 1500V and continuous current handling up to 500A or more under certain conditions. Its bi-directional switching capability ensures reliable operation during both charging and discharging cycles. To withstand these conditions, contactors must have high interrupting capacities to manage overcurrent without failure. Arc-resistant silver alloy contacts and robust construction further enhance durability and performance in demanding high-power environments.

2. Thermal Management and Contact Materials

Efficient thermal management is critical for preventing overheating in high-power applications, where high currents generate significant heat. Contact materials such as silver-tin-oxide offer high thermal conductivity and resistance to oxidation, ensuring reliable performance over time. The C303, for example, uses arc-resistant silver-tin-oxide alloys to minimize contact resistance and reduce heat generation, maintaining long-term reliability.

3. Compact and Space-Efficient Design

As ESS installations become more compact, modern contactors are designed to maximize space efficiency. The C303 contactor features a compact form factor, allowing it to fit into smaller enclosures without compromising performance or safety. This space-efficient design makes it ideal for applications where space is at a premium. Its ability to integrate seamlessly into high-density energy storage systems further underscores its versatility. 

By combining high current capacity, efficient thermal management, reliable switching, robust open-air design, and a compact design, modern contactors like the C303 offer reliable, cost-effective solutions for the evolving needs of ESS. These features are essential for minimizing downtime, reducing energy losses, and ensuring long-term system efficiency. The extended service life, low maintenance requirements, and high performance make modern contactors a critical component for achieving optimal performance and long-term reliability in ESS.

The Future of Contactor Technology in ESS 

The future of ESS will be shaped by ongoing innovations in contactor technology. Advancements in design, materials, and integration with emerging technologies—such as sensor integration and communication—will enable contactors to handle higher power capacities, improve thermal management, and increase energy efficiency. These developments will ensure that ESS remain sustainable and capable of meeting the demands of a renewable-powered future. 

Modern contactors already provide features like high current capacity, reliable switching, and exceptional durability. As ESS continue to grow in importance, selecting advanced contactor technology will be critical for maximizing efficiency, reliability, and long-term safety in energy systems. Additionally, AI and sensing technologies are enabling predictive maintenance and smart energy management, which will enhance the performance of ESS by proactively addressing issues before they lead to failure. 

Full focus on our purpose and vision 
Enabling society to unlock the full potential of electrification for a more sustainable future is a promise that continues to be rooted deeply in our business, as is our commitment and passion for safety on rail. Our vision is to be a global leader in DC technology – that’s why we have taken time to expand our footprint in the fast-growing e-mobility and energy markets. By launching Eddicy in spring 2024, together with our updated Schaltbau branding, we underscore our ambition to provide our energy and e-mobility customers with solutions that make their products safer and more efficient. 

Read more about our vision, mission, values and the launch of Eddicy here. 

And the winner is … Schaltbau’s NExT Factory 

Advancing our portfolio of solutions and innovations is both demanding and challenging at times. Our NExT Factory in Velden, Germany, however is living – concrete – proof that grit pays off: During its first full year of operation, the CO-neutral factory literally took the limelight by winning numerous industry awards, including the German Energy Agency’s “Energy Efficiency Award 2024”, the “German Award for Sustainability Projects”, and the “German Innovation Award.” 

The world’s first DC factory saves up to 35% in annual energy costs by its direct current microgrid, intelligent energy management as well as battery and thermal storage. Our hope for it to become a blueprint for others by setting a new standard in industrial energy efficiency and demonstrating scalable strategies for reducing CO₂ emissions was certainly nourished by these awards as well as by the hundreds of visitors from across the industry and world which flocked to the factory this year. 

Learn more about the NExT Factory here. 

Fast-tracking bidirectional DC applications 

Safely charging and discharging direct current is a prerequisite for many of the energy and e-mobility applications paving the way towards climate-neutrality. Not only do they need to fulfil the highest safety, performance and reliability standards, they also need to withstand the most demanding environments. In 2024, we introduced the first addition to our Eddicy portfolio of products for energy and e-mobility: our fully bidirectional C303 industrial DC contactor series. Engineered for high inrush currents, C303 contactors have a making capacity of 2,000 amps, continuously carry up to 350 amps, and withstand short-circuit currents of up to 4,000 amps for 20 milliseconds. 

Despite being the smallest in its product family, it delivers unmatched performance in industrial DC applications, such as stationary charging infrastructures, energy storage, battery test benches, DC microgrids, non-IATF electric vehicles, vehicle-2-grid and intralogistics. 

Discover more about our C303 here.

Meeting our customers and partners 

From trade fairs in Korea, USA, UK and France where we first presented Eddicy to customers, to Hannover Messe, the Battery Show Europe and ees Europe: Schaltbau spent a fair bit of time on the road to introduce our new products and gather customer feedback. One trade fair that we will particularly remember: the 2024 InnoTrans in Berlin, the world’s largest trade fair for transport technology. With 2940 exhibitors and 170,000 (!) visitors from 133 countries, it was an excellent opportunity to meet with customers, partners, politicians to showcase our expanded high-power contactors (CP and CF series) for high-demand rail applications. Those bustling days in Berlin, if anything, showed the tremendous momentum for reducing emissions, improving energy efficiency, and driving the digital transformation of transportation. 

The future (device) is smart 

Schaltbau will also look back to 2024 as the year in which we first introduced smart devices – namely, the Smart Circuit Breaker, an intelligent switching device for critical energy applications. Equipped with integrated sensors, real-time monitoring, and self-diagnostic capabilities, it cuts off short-circuit currents ten to a hundred times faster than conventional contactors, detects overcurrents early, measures and assesses fault currents and collects critical data points. Consequently, it improves energy management and can help to significantly minimize downtime. 

Read the announcement of our Smart Circuit Breaker here.

Our wish for 2025 

A sustainable future is an electrified one – and direct current can make a significant contribution towards net zero by eliminating major inefficiencies. Sourcing more energy from renewable sources is critical, along with the need to increase energy efficiency and reduce energy waste in all sectors. The more we can avoid or reduce costly conversion losses between DC and AC in the industrial, energy and mobility sectors, the better. We are as eager as ever to contribute to the energy and e-mobility DC infrastructure of the future and remain committed, as always, to the safety on rail. 

The numbers speak for themselves – rail travel and freight account for a mere 1% of transport emissions, a staggering contrast to road traffic (74.5%), aviation (11.6%), and shipping (10.6%).¹ This environmental edge is fueling a resurgence in rail's popularity, as passengers and freight operators alike seek out more sustainable mobility options. However, there's still work to be done since challenges such as the high energy consumption and the complex power distribution within trains remain. 

Electrification lies at the heart of sustainability in rail. The industry's global energy mix is shifting, with electricity accounting for more and more of the share . Currently, the International Union of Railways (UIC) estimates that approximately 50% of current global rail energy use comes from electricity.² This transition, coupled with the integration of renewable energy sources, is a game-changer for emissions reduction. 
Despite being comparably small, electromechanical components play their role in the electrification journey Solutions that have less weight, less resistance, consume less power and have a longer lifetime contribute to more energy savings and sustainability at any electrical connection within the train. In addition, advancements in traction motors, power electronics, and control systems are enhancing the performance and efficiency of electric and hybrid trains, expanding their range and capabilities. 

The rail industry is also leveraging regenerative braking and energy storage systems to minimize energy waste and boost efficiency. In modern systems, remaining energy loss is mostly the result of friction and electrical resistance. Regenerative braking systems capture and store kinetic energy during braking, which is then converted and reused for accelerating the train or powering onboard systems. Energy storage systems utilize mostly batteries to efficiently manage and store regenerated energy, reducing overall energy consumption and enhancing efficiency. 

Electromechanical connectors and contactors also contribute to sustainable rail infrastructures, enabling better power distribution and data/signal transmission with minimal energy losses. Innovative designs and materials contribute to this efficiency, ensuring precision, safety, and reliability in even the harshest operating conditions. Schaltbau’s electromechanical components contribute here by connecting or isolating the flow of energy with minimized losses (e.g.by contact resistance) and safe operation over the full range of demand. 

Sustainable Manufacturing: Paving the Way for a Greener Future 

Sustainability in the railway industry extends beyond operations and includes the industry's manufacturing processes. Pioneering companies are leading the way, embracing carbon-neutral factories, recycled materials, and other eco-friendly practices to minimize the environmental impact of rail production. We’re proud that our design and manufacturing processes guarantee precision and efficiency, use recycled materials and reduce environmental impact during production at our NExT Factory in Velden, Germany. 

The potential benefits of embracing innovative rail technologies are evident. By diversifying energy sources and providing more efficient mobility, the rail sector can further reduce transport-related emissions and help combat the global climate crisis.³ As the world becomes increasingly conscious of its environmental impact, the rail industry is positioned to play a pivotal role in the transition towards a greener, more sustainable future. 

Through the strategic implementation of electrification, energy-efficient infrastructure, smart technology, and sustainable manufacturing, the rail industry can drive this transformative shift. These topics and more will take center-stage at this year’s upcoming InnoTrans, the leading international trade fair for transport technology, taking place in Berlin on Sep 24-27. 

Join us there to learn more about how the latest advancements in electromechanical components can power the future of sustainable rail. Our team will be on hand to showcase our innovative products and solutions. We look forward to connecting with you there! 

Learn more about InnoTrans here!
 

References: 

1. Ritchie, H. (6. Oktober 2020). CO2-Emissionen aus dem Verkehr, 1990-2018. Unsere Welt in Daten. https://ourworldindata.org/co2-emissions-from-transport
2. Internationaler Eisenbahnverband (UIC). (2022). Global Rail Sustainability Reportr 2022 (S. 23). https://uic.org/IMG/pdf/global-rail-sustainability-report-2022.pdf
3. Internationale Energieagentur (IEA). (30. Januar 2019). Railways could provide much greater benefits for energy and the environment, according to IEA report. https://www.iea.org/news/railways-could-provide-much-greater-benefits-for-energy-and-the-environment-according-to-iea-report

Let's examine the important role of connectors, the change of technologies in intralogistics, and how to close the gap between customer needs and these developments. 
A look into the future of intralogistics and how connectors fit in: 

Digital twins and simulation: virtual replicas of physical assets or processes are being adopted more and more to optimize operations and improve decision-making. Communication is key as it helps operators use these models to predict and mitigate potential disruptions, optimize resource allocation, and enhance overall efficiency—and, you guessed it, connectors facilitate this critical communication. Connectors guarantee the seamless transfer of power, data, and control signals, which is vital for the operation of automated guided vehicles (AGVs), conveyor systems, and robotic arms as well as the established forklifts. 

Autonomous vehicles: it is predicted that the use of autonomous vehicles in intralogistics will continue to increase, especially in warehouse and distribution centers. These technologies offer benefits such as improved accuracy, efficiency, and safety in tasks such as inventory management and goods transportation. Connectors help integrate these technologies into existing systems to ensure seamless coordination, safety, and smooth operation. 

Lithium-Ion Batteries: The share of lithium-ion batteries in electric forklifts is increasing. To ensure faster charging cycles, longer lifespans, and higher efficiency compared to traditional lead-acid batteries, specially adapted charging connectors are needed. 

Internet of things (IoT) sensors: IoT sensors are becoming increasingly prevalent in intralogistics for real-time monitoring and tracking of goods, equipment, and environmental conditions. These sensors collect data on parameters such as temperature, humidity, location, and vibration, enabling logistics operators to optimize inventory management, ensure product quality, and proactively identify and address potential issues such as spoilage or damage during transit. 

These vast amounts of data need to be integrated into logistics systems for real-time monitoring and decision-making. By providing standardized interfaces and protocols for data exchange, connectors facilitate the aggregation and analysis of IoT sensors data, supporting predictive maintenance, inventory optimization, and quality control efforts. For data transfer in intralogistics applications, cables and connectors will continue to be crucial in the future. 

Predictive analytics and Artificial Intelligence (AI)-driven optimization: Predictive analytics and AI are leveraged more and more to forecast demand, optimize inventory, and optimize transportation routes and schedules. By analyzing historical data, market trends, and other relevant factors, predictive analytics algorithms can anticipate future demand patterns and supply chain disruptions, enabling logistics operators to make informed decisions and adapt strategies accordingly. Connectors enable the integration of data from various sources, allowing operators to maximize the use of predictive analytics and AI tools. 

Sensor technology for safety: Sensor technology is changing safety in intralogistics by providing real-time monitoring and tracking of goods, devices, and environmental conditions. Advanced sensors in connectors capture and manage data on critical parameters like temperature spikes caused by high loading currents. A sophisticated locking mechanism, equipped with a switching element, ensures safe, load-free disconnection of the system, while an integrated CAN bus continuously oversees the charging processes. This seamless integration of sensors not only enhances operational efficiency but also significantly mitigates risks, ensuring a safer and more reliable intralogistics environment. 

Ergonomic Design: Ergonomic design enhances operator comfort and reduces fatigue through adjustable seats, intuitive controls, and better visibility. From the user's perspective, connectors are essential to integrate these features effectively, ensuring seamless and reliable operation of the adjustable and ergonomic components. 

Sustainable and green logistics: with sustainability on the rise, there is a growing emphasis on adopting green logistics practices, including things like energy optimization or waste reduction. Connectors allow the integration of new technologies and processes into existing systems. For example, they help bring renewable energy sources into warehouse management systems or transportation management systems, allowing logistics operators to optimize energy usage and reduce environmental impact. 

Intralogistics is being shaped by emerging trends that are changing the way we think about warehouse and distribution processes. And, as you can see, connectors play an important role in addressing common challenges and paving the way for more innovative solutions in the future. 

Want to learn more?

Are you curious to learn more about  certain challenges of intralogistics and see first-hand how Schaltbau connectors can provide a solution? The join our upcoming webinar taking place on Thursday, July 18th. Don't miss out - register now! 
 

What’s more, the inclusion of women in engineering teams has been shown to improve company performance and project outcomes. According to a report by McKinsey, companies with gender-diverse executive teams are 21% more likely to experience above-average profitability . This statistic highlights that gender diversity is not just a matter of social equity but a critical business strategy. 

Yesterday was International Women in Engineering Day and on this occasion, we’d like to celebrate our diverse and talented workforce by highlighting inspiring female talent at Schaltbau. We hope this encourages more women to enter and thrive in engineering careers, ensuring a richer, more dynamic, and ultimately more successful engineering landscape, capable of meeting the challenges of the future. 

We talked to several women in (science, tech, engineering, and mathematics) STEM at Schaltbau, each in different technical positions and from different backgrounds. Carina is a Senior SAP Consultant EWM at Schaltbau and has worked in a technical role her whole career, entering IT in 2016. When asked about her motivation for a technical career in IT, she states “I think the technical field is extremely innovative, as everything is changing so quickly. In general, I like everything that is automated.” But it wasn’t always her plan, “at the end of my studies, I didn't want to go into IT. I couldn't imagine working in such a field. Also because of the prejudices I had. Nevertheless, my first IT team got me so involved in the subject that I still enjoy working in this area today.” 

We also talked to Veronika, a production planner for NExT Factory. Veronika started her career in the commercial field but pivoted to a technical role because of her personal interests, “my father himself is a self-employed mechanical engineer and I always worked with him and had the opportunity to travel to customer appointments. That was my first experience in tech and it sparked my enthusiasm for such an environment.” 

Others like Grete, a snap switch development engineer, started in engineering right after graduation, “I've always had a fascination for science, especially engineering,” she says. “There's a certain amount of creativity that you can bring to the table when you're creating something new. I would say that was what inspired me to choose a technical career.” 

Whether it’s production planning, the development and construction of our products, or process optimization for warehouse management, Schaltbau’s workforce is made stronger through diverse talent. While there are many positive aspects to being a woman in engineering at Schaltbau, there are also some challenges. For example, being perceived as insecure or shy, or feeling like you must go above and beyond to prove yourself. However, there are always ways to overcome challenges and Veronika advises women in STEM to “communicate as equals.” She also sums it up differently, saying “I believe that the question is much more about what advantages everyone brings with their strengths. Regardless of gender. I believe that diversity in general enriches the corporate culture and has a direct impact on the company's success.”

When asked what they might say to young girls considering a technical career, they had some great advice. Carina says, “trust in yourself, you can do it and you will do it!” Veronika encourages girls to “have the courage to take a different path and not be guided by the majority or stereotypes at school.” And finally, “if you are really interested in a profession, you will be successful,” Grete adds. 

The future of engineering is bright, and it is brimming with opportunities for young women ready to make their mark. By pursuing careers in STEM, young women can not only achieve their personal and professional dreams but also contribute to the global quest for innovation and excellence. Industry needs their unique insights, their creativity, and their determination. As barriers continue to fall and support for women in engineering grows, now is the perfect time to seize the moment and step confidently into these fields. 

Embracing a career in STEM is not just a choice for a brighter future; it's a chance to be part of the dynamic force shaping our world for generations to come. So, to all the aspiring female engineers out there: your journey is just beginning, and the possibilities are as vast as your ambition. The world is waiting for you to make your impact. 

To learn more about careers at Schaltbau, visit https://www.schaltbau.com/en/company/career/ 

• Safe disconnection of the battery unit: Schaltbau contactors can handle high-voltage arcs that can occur when switching DC loads. In case of maintenance or an emergency shutdown, they ensure a safe disconnection of the battery unit from the inverter in energy storage systems. 
• Increased system efficiency: Due to their low contact resistance and low energy consumption, they contribute to overall efficiency of the energy transfer to and from the battery and minimize heat dissipation: to transfer the energy and not to lose it. 
• Full bi-directionality: Schaltbau’s DC contactors ensure the safe disconnection of high power regardless of the current direction. They safely manage potential fault modes in both directions of current flow. 
• High breaking capacity: DC contactors meet the high requirements for breaking capacity of industrial storage systems, leading to increased system availability and improved total cost of ownership (making capacity, continuous thermal current, rated short-time withstand current). 

The global energy storage market is projected to grow rapidly – at a compound annual growth rate (CAGR) of around 10% within this decade. Apart from the obvious environmental advantages of integrating a higher share of renewables, there are also fundamental economic benefits for enterprises wanting to integrate renewable energy generation and on-site storage systems. 

Energy storage is a smart move for business, not just the environment 

Electricity purchase prices are calculated according to a formula that includes the peak loads drawn and the provision of sufficient capacity. These provision charges must be paid for the entire billing period, even though the peak load capacity might only be used for a fraction of the time. Energy storage enables energy to be saved for later use. Consequently, it allows businesses to avoid higher tariff charges, reduce operational costs and save on their electricity bills. 

In addition, energy storage solutions supply energy continuously even when the network is unstable due to peaks or extreme weather events, thus reducing grid dependency. Energy storage facilities also provide back-up power in the event of an outage guaranteeing business continuity. 

Energy storage will be crucial for the world to accelerate its journey towards net zero. Sophisticated industrial components, such as DC contactors, connect renewable energy sources, energy storage systems and electrical consumers without the energy losses that occur when direct current is converted to alternate current. In the quest for carbon-neutrality, the paradigm shifts toward renewable energy generation and advanced energy storage systems, creating the energy solutions for a better tomorrow – and Schaltbau is there every step of the way. 
 

Read more about Schaltbau contactors and Eddicy energy storage solutions here. 
 

References:

1. International Energy Agency. (2021). Net zero by 2050: A roadmap for the global energy sector. International Energy Agency.
2. Statista. (n.d.). Energy storage. Retrieved June 12, 2024, from https://www.statista.com/topics/4632/energy-storage/#topicOverview
3. European Commission. (n.d.). Recommendations on energy storage. Retrieved June 12, 2024, from https://energy.ec.europa.eu/topics/research-and-technology/energy-storage/recommendations-energy-storage_en

With energy efficiency and sustainability at the forefront of everyone’s mind, industries are seeking innovative solutions for their manufacturing needs. The emphasis on optimizing energy consumption and reducing carbon footprints becomes more and more pressing. As the global community rallies behind initiatives to combat climate change and foster sustainable development, industries are tasked to rethink their operational frameworks and integrate new technologies that prioritize environmental responsibility without compromising productivity. So how can we do that? Two words: direct current. 

Direct current (DC) microgrids are here to change industry as we know it. By decentralizing power generation and storage as well as reducing the number of energy conversion stages, resulting in minimized energy losses, DC microgrids not only enhance operational efficiency but also empower manufacturers to navigate through fluctuating energy demands with resilience and agility. What’s more, their compatibility with renewable energy sources drives sustainability efforts and fosters eco-friendly practices while reducing dependency on traditional power grids. 

DC microgrids leverage unique features such as reduced points of failure, energy storage integration, islanding capability, advanced control systems, distributed generation, and predictive maintenance, to offer uninterrupted power supply. Let’s dive deeper into these benefits and learn more about how DC microgrids are leading us into a new era of innovation and sustainability: 

Reduced Points of Failure

DC microgrids significantly reduce points of failure compared to traditional AC systems by simplifying the overall architecture and minimizing conversion stages. With fewer components involved in energy transmission and distribution, the risk of system failures and downtime is greatly reduced, enhancing the reliability of manufacturing operations. This streamlined approach not only improves system efficiency but also lowers maintenance requirements, resulting in cost savings and increased operational uptime.

Energy Storage Integration

DC microgrids are well-suited for integrating energy storage systems such as batteries. By storing excess energy during periods of low demand or high renewable generation, these microgrids can ensure a constant power supply even when renewable sources like solar or wind are not producing electricity. 

This integration enhances flexibility and resilience, allowing manufacturing facilities to better manage energy costs and optimize their power usage. Additionally, energy storage integration facilitates smoother integration of intermittent renewable sources, ensuring a reliable and consistent power supply for critical manufacturing processes. 

Islanding Capability

One of the key features of DC microgrids is their ability to operate autonomously or in "island mode" when disconnected from the main grid. In the event of a grid outage or disruption, DC microgrids can easily transition to island mode, ensuring uninterrupted power supply to critical loads within the microgrid's network. 

This ensures uninterrupted operation of critical equipment and processes, minimizing disruptions and preventing costly downtime. Islanding capabilities enhance the resilience of manufacturing operations, safeguarding against external power disturbances and increasing overall system reliability. 

Enhanced Control & Monitoring 

DC microgrids feature advanced control and monitoring systems that provide real-time insights into energy generation, consumption, and distribution. Utilizing sophisticated sensors and communication technologies, these systems collect data from various microgrid components, enabling operators to access comprehensive dashboards and visualization tools displaying key performance indicators and energy flows. This visibility empowers operators to identify inefficiencies, detect abnormalities, and optimize energy distribution to meet demand while minimizing waste. 

Additionally, DC microgrid controllers employ advanced algorithms and machine learning techniques to analyze incoming data, dynamically adjusting generation levels, prioritizing loads, and implementing demand response strategies. In the event of grid disturbances, the control system swiftly reconfigures the microgrid to maintain stability by autonomously isolating faulty components, rerouting power flows, and implementing load shedding measures to prevent system-wide failures. 
 

Distributed Generation Integration

DC microgrids can easily integrate distributed generation sources such as solar panels or small-scale wind turbines. By leveraging distributed generation, microgrids can diversify their energy sources and reduce reliance on centralized power plants, thereby increasing overall system reliability. 

By efficiently harnessing renewable energy at the point of generation, DC microgrids reduce reliance on the traditional grid and enhance the resilience of manufacturing operations against power disruptions. 
Distributed energy integration in DC microgrids fosters energy independence and sustainability for manufacturing facilities. By optimizing the use of renewable resources and storage capabilities, these microgrids minimize reliance on fossil fuels and reduce greenhouse gas emissions, aligning with both environmental goals and cost-saving objectives. 

This comprehensive approach to distributed energy integration empowers manufacturing facilities to achieve greater energy efficiency, resilience, and sustainability, ultimately driving long-term operational benefits. 

Predictive Maintenance

With advanced monitoring and analytics, DC microgrids deploy predictive maintenance strategies by continuously assessing the health and performance of critical components like power electronic units and energy storage systems. Sophisticated algorithms analyze historical data and sensor readings to detect subtle changes, while machine learning enhances predictive capabilities by identifying patterns and correlations. When issues are detected, alerts prompt proactive maintenance actions, allowing operators to address problems before they escalate. 

This approach minimizes downtime, lowers repair costs, and extends component lifespan, ensuring continuous operation and reliability for enhanced system performance and customer satisfaction. 

As you can see, DC microgrids are transforming the manufacturing landscape. By decentralizing power distribution, integrating renewable energy sources, enabling real-time monitoring and more, DC microgrids not only enhance operational efficiency but also future-proof industry, building resilience against fluctuating energy demands and external disruptions. We’re entering a new era of innovation and sustainability, where industries can thrive while prioritizing environmental responsibility. 

Want to read more about DC microgrids and Eddicy solutions that can help meet your needs? Click here to learn more about Schaltbau contactors for microgrids.  

Providing enhanced energy efficiency, flexible power flow control, and extended battery lifespan in various industries, bidirectional contactors facilitate energy recovery in electric vehicles, smooth transitions between charging and discharging in energy storage systems and improve the economic viability of e-mobility. But when it comes to available options, what features are key for superior performance? 

As the name suggests, they must excel at controlling electrical power flow in both directions, enabling dynamic power management for applications like energy regeneration, bidirectional charging, and grid interconnection. Unlike unidirectional contactors, they offer engineers a two-way path, optimizing energy utilization and enhancing system resilience with remarkable flexibility. 

Key Operating (KO) criteria are crucial in bidirectional contactor design, ensuring top performance, reliability, and safety in varied conditions. That’s why it’s important to consider parameters such as contact resistance, switching speed, voltage, current ratings, durability, and environmental robustness. Adhering to these criteria ensures consistent, reliable operation, even in tough industrial environments, safeguarding system integrity and longevity. 

Low contact resistance, for example, reduces power losses and heat dissipation. Through advanced material selection, precision engineering, and innovative designs, contact resistance is minimized, optimizing energy efficiency and system performance. This reduction not only improves power transmission efficiency but also extends the contactor's lifespan, reducing maintenance needs over time. 

With Eddicy, our brand for energy and e-mobility, we’ve released the C303 contactor that meets these strict technical criteria with the following features: 

• Unmatched short-circuit resilience: The ICM handles 15kA/5ms, double that of competitors, ensuring robust performance and reducing risks during short circuits. 
• Enhanced safety: Our latest contactor series is non-gas encapsulated, extending lifespan and safety by eliminating explosion risks and ensuring controlled responses to danger. 
• Impressive overload capability: The bidirectional contactor handles 8,000 A for 20 milliseconds without causing fires, with non-welding contacts ensuring timely fuse triggering for added safety. 
• Low resistance and temperature rise: With low contact resistance, it surpasses competitors like WB, generating less heat during installation for energy-efficient operation and environmental sustainability. 
• Provides full plug-and-play capability, simplifying installation, integration, and maintenance processes. 

Bidirectional contactors are crucial for global sustainability, enhancing energy efficiency, grid integration, and renewable energy use. They help us reduce greenhouse gas emissions, foster energy independence, and empower society to engage in the energy transition on every level. 

Join us in embracing these solutions as we progress towards a sustainable and electrified future. Learn more about our C303 contactor series here.

With the growing number of devices generating and using direct current, such as solar panels, wind turbines or batteries, comes the opportunity to facilitate the transformation to a climate-neutral economy. By distributing DC power to DC devices, it is possible to avoid substantial energy losses that occur when electricity is converted. Eddicy products are designed to unlock the full potential of electrification as they reliably switch, connect, control, and protect DC applications such as charging, energy storage stations, and electric vehicles of all kinds.

As a global market leader in direct current (DC) technology, Eddicy, a new sub-brand of Schaltbau, will cater to customers in energy and e-mobility and to serve them with a differentiated portfolio of products customized to their industrial needs.

Edison + DC = Eddicy

The name Eddicy and its logo symbolize Schaltbau’s expertise in direct current technology as well as its forward momentum: It is derived from direct current proponent and American inventor Thomas Alva Edison and the abbreviation "DC" for direct current. In the Eddicy logo, the dots above and below the "i" represent a positive and negative charge and the "i" with its two dots resembles an early Edison DC generator.

Today, direct current (DC) generators have a myriad of uses across various industries. In the automotive industry, they are for instance used in cars for battery charging systems. And in the energy sector, the use of DC generators in renewable energy sources has further increased their significance in recent times. Eddicy stands for the dynamism of direct current applications in these new markets and for the passion, agility, and innovation it takes to play a leading role in them.

 

Driving Schaltbau’s evolution

The launch of Eddicy is part of a broader corporate brand refresh at Schaltbau. The brand update reflects the commitment to deliver pioneering solutions that help electrify the world. It also underscores the company’s drive to further strengthen its core business as a trusted supplier in the global rail market which Schaltbau will continue serving together with SPII.

Guided by quality, passion, partnership, and agility, Schaltbau is on a mission to unlock the full potential of electrification. And, as global technology leaders for DC, Schaltbau aims to set the benchmark for safety and efficiency in an electrified world that is connected by advanced technology, fueled by innovation, and powered by a commitment to a better tomorrow.

Key features of the launch of Eddicy and corporate brand refresh include modernized logos, a redesigned website, and newly defined corporate mission, vision and values that reflect the strategic focus of the organization. The branding will be rolled out globally in the coming weeks and months to customers, partners, and stakeholders alike.

Explore our updated website at www.schaltbau.com and stay connected on our LinkedIn account for Schaltbau and Eddicy news.