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

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

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

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

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

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

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

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

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

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

For more information about the event, visit here.  

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.

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.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

... yet significant challenges persist

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

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

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

V2G-ready contactors: Engineering challenges in bidirectional power systems

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

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

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

EVs: More than decarbonization of transport

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

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

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

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

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

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

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

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

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

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

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

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

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

Schaltbau, a global leader in advanced DC technology, is proud to announce the newest addition to its Eddicy portfolio, the C803 contactor, specifically designed for e-mobility applications. This bidirectional contactor sets a new benchmark in performance, robustness, and efficiency for commercial vehicles, off-road equipment, and passenger cars, meeting the rigorous demands of the rapidly evolving electric vehicle (EV) and industrial vehicle markets.

The C803 is engineered for high performance in a compact form, making it ideal for a range of applications whether they require inverters, charging systems, or auxiliary power systems. While optimized for demanding environments such as off-road and commercial vehicles—offering robust performance in extreme conditions—the C803 is also ideal for passenger car use.

Key Features of the C803 Contactor:

• Low thermal losses: The C803 has a low contact resistance of about 100 µOhm, which reduces the need for additional cooling and solves thermal management challenges
• High performance in compact design: With a switching voltage of 1,500V and high switching currents and a compact weight of under 0.5 kg, the C803 is ideal for inverters, charging, and auxiliary applications
• Robust for off-road use: Designed to withstand 200,000 operations and resist vibration per ISO 16750-3, the C803 is built to meet the demands of trucks, excavators, and other heavy-duty vehicles
• Versatile application: The C803 works across a wide range of e-mobility systems, from industrial vehicles to passenger cars, with support for vertical or horizontal mounting and compliance with global safety standards

With a focus on minimizing thermal issues, the C803 is designed to reduce the need for extensive cooling systems, which are often a challenge in e-mobility applications. Its advanced low-loss design ensures excellent efficiency without the need for excessive heat management, providing significant advantages in reducing cooling demands in electric drive systems. This capability is particularly valuable in e-mobility, where optimizing energy efficiency is key to improving overall system performance.

“The C803 is unique in how it tackles the most challenging thermal and efficiency problems in the industry—because in high-power switching, heat is the enemy of performance,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “Engineered for superior thermal management, the C803 minimizes heat buildup, extends operational life, and ensures maximum efficiency even under extreme loads. When every degree matters, the C803 stays cool—so systems run safer, longer, and more reliably.”

The C803 is a DC bi-directional/AC contactor with a 1,500V switching voltage. It offers  a thermal current rating of 500A. It includes a snap-action auxiliary contact with silver material, compliant with IEC 60947-4-1, annex F. The auxiliary contact operates at 5V/10mA and connects via a 5-pole connector. The monostable magnetic drive supports 12V or 24V DC control voltage with internal and external pulse width modulation (PMW) options. Built for durability, it withstands 200,000 operations, resists vibration per ISO 16750-3, and operates from -40°C to +85°C. It supports vertical or horizontal mounting, weighs under 0.5 kg, and complies with global safety standards.

The C803 is the newest addition to Eddicy’s e-mobility portfolio, complementing the existing C800 and C801 models. 

Visit here for more information about the C803 or to request a product demonstration.

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.

Schaltbau, a global leader in direct current (DC) technology, has been selected to supply its bidirectional high-voltage C800 contactor as well as its HV connector for an electric truck series by a leading European OEM, known for light, medium, and heavy commercial vehicles. The development partnership, the production order starting mid-2025 with a duration of several years, as well as on-going discussions about the manufacturer’s upcoming megawatt-charging projects are testament to the successful positioning of Eddicy as a trusted supplier for a wide range of e-mobility applications.

The C800 series will be used in the truck’s power distribution unit (PDU), ensuring maximal safety, performance and durability – especially in battery emergency cases, in which the contactor safely disconnects the current to safeguard vehicle, driver and freight. The bi-directional Eddicy contactor is notable for its high current carrying capacity and its high energy efficiency, making it perfectly suited to switch power in a small space and in applications with energy recovery, such as the PDU of modern e-vehicles. The C800 has a making capacity of up to 4,500 amps, can permanently carry up to 5,000 amps and, in the event of a short circuit, even 6,000 amps may flow for 20 milliseconds without the contacts welding. Thus, the contactor retains its full function to switch large power when required, regardless of the direction of the current. Schaltbau’s HV connectors will be used in connection between truck and trailer to enable safe power to auxiliary refrigeration systems.

“We are pleased to have been chosen for a truck series which will combine the longer service life and lower maintenance of electric truck drives with a much lighter environmental footprint,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “Global demand for battery-powered commercial vehicles is increasing rapidly. With our high-power contactors, we contribute to bigger ranges, faster loading speeds and operational safety, thus supporting the transition towards more electric road transport across all vehicle classes.”

To achieve comparable power in electric trucks as in conventional combustion truck engines, high DC voltages are indispensable. Schaltbau’s contactors play a crucial role in the truck’s safety circuit: They reliably switch high currents during normal operation and ensure the galvanic isolation of both poles of the high-voltage battery from the vehicle’s high-voltage grid in the event of a short-circuit or thermal overload. Hence, they protect the vehicle, its occupants and transported goods. 

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.}

"For decades, Schaltbau contactors have powered some of the world’s most demanding rail applications," said Steffen Munz, CEO of Schaltbau GmbH Group. “Today, that same field-proven technology is driving innovation in high-power industries like mining, construction, and test benches—setting new benchmarks for safety, efficiency, and durability in every connection.”

From energy conversion and storage to test benches and off-road e-mobility, CP and CF contactors are designed to handle voltages and currents with precision and reliability. With up to 25% energy cost savings due to low contact resistance and reduced contact heating, these high-power contactors offer full bidirectionality thanks to their specially designed arc-extinguishing chamber.

The expanded CP series includes three new variants—rated at 800A, 1000A, and 1500A— engineered to perform seamlessly under heavy load conditions, even in high-vibration, high-contamination settings. The arc-handling is done exclusively by permanent-magnetic blowout. This patented technology ensures fully bi-directional breaking capability and a more compact design, reducing dimensions, weight and required space. Additionally, the series also includes the Smart-CP contactor, a next-generation intelligent switching device prototype. Equipped with integrated sensors, real-time monitoring, and self-diagnostic capabilities, it will bring intelligence into critical power applications, improving energy management and reducing downtime.

 The CF series offers a modular approach with contactors available with up to 6 main contacts in both NO (normally open) and NC (normally closed) configurations, handling currents up to 400A and voltages up to 3000V. The CF series can switch both alternate current (AC) and direct current.

Eddicy products are designed to unlock the full potential of electrification for a more sustainable, carbon-free future as they reliably switch, connect, control, and protect DC applications in energy and e-mobility such as charging stations, energy storage systems, and electric vehicles of all kinds. DC applications and products that switch, protect, and secure high-voltage power play a crucial role in the transformation to a climate-neutral economy. 

Technical details:

 CP series: 

• Current range: 600A to 2000A, with the three new versions rated at 800A, 1000A, and 1500A. 
• Voltage range: Nominal voltages of 1.5kV to 3V, suitable for both AC and DC loads. 
• Mechanical life: Over 1 million switching cycles for NO and NC contacts, making them highly durable in harsh operating conditions. 
• Configuration flexibility: The CP contactors feature 3 arc chamber types (A, B, D) and come with a monostable or bistable drive system, ensuring broad applicability and easy customization for e-mobility and energy applications. 

 CF series: 

• Current ratings: Available in 200A, 300A, and now 400A models, providing a scalable solution for different power needs. 
• Switching chambers: Each variant is built with up to six poles (for 200A/300A models) or four poles (for the 400A model), with fully bi-directional switching for both AC and DC loads. 
• Mechanical life: With over 1 million cycles, the CF series delivers longevity, reducing the need for frequent maintenance. 
• Operational flexibility: The modular design supports up to four auxiliary contacts (S870 or S826), enhancing its applicability across a variety of operational conditions. 
• Critical current resilience: The CF series is engineered to handle high short-circuit withstand currents of 4kA without critical current range issues. 

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. 

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! 
 

Schaltbau, a global leader in direct current (DC) technology, will showcase innovative Eddicy solutions for energy storage and battery technologies at “The Battery Show Europe,” which will take place in Stuttgart from June 18-20, 2024; and the “ees Europe,” from June 19-21, 2024 in Munich. 

Whether it’s energy storage systems, charging infrastructures, or electromobility, DC technology is more critical now than ever before. A key component in the transition to renewable energy, DC power must be leveraged for efficient and reliable use—and Schaltbau’s line of Eddicy bidirectional contactors make that a possibility. 

Highlights will include the C303 contactor, engineered for bidirectional DC applications and offering unmatched performance suitable for a range of uses in energy storage, charging stations, electric vehicles, and vehicle-to-grid (V2G). With a very low contact resistance of slightly over 100 µΩ, the C303 offers best-in-class performance with low contact warming and low power loss due to optimized contact pills. The coil drive with fast switch on and AgSnO2 contact tips result in superior performance in short time currents (5kA capacity for 20 milliseconds without contact welding) and high making capacity (currents up to 2kA without contact welding). The smallest Schaltbau contactor for 350A Thermal current, the C303 offers complete plug-and-play capability. 

The company will also showcase the new C800 bidirectional contactors for e-mobility applications. With a making capacity of up to 4,500 amperes and continuous current carrying capacity of up to 500 amperes, they are ideal for use in the Battery Disconnect Unit (BDU) of electric vehicles. They can even handle short-circuit currents of up to 6,000 amperes for 20 milliseconds without the contacts welding, maintaining full functionality to switch large currents, such as up to 1,200 amperes at 450 volts, regardless of the current direction. 

Attendees are invited to meet Schaltbau at each event to explore how these bidirectional contactors can enhance energy sustainability and resilience: 

Eddicy at The Battery Show Europe 
Date: June 18-20, 2024, Stuttgart, booth 8F35 

Eddicy at ees Europe 
Date: June 19-21, 2024, Munich, booth B2.381 
 

For more information about each event, please visit us here:  https://www.schaltbau.com/en/news/trade-shows/the-battery-show-ees-europe/ 
 

• Fully bidirectional, meeting key operational (KO) criteria for applications such as energy storage, charging stations, electric vehicles, and vehicle-to-grid (V2G) 
• Very low contact resistance of slightly over 100 µΩ, best-in-class performance with low contact warming and low power loss due to optimized contact pills 
• Properly designed coil drive with fast switch on and AgSnO2 contact tips result in superior performance in short time currents (5kA capacity for 20 milliseconds without contact welding) and high making capacity (currents up to 2kA without contact welding) 
• High diagnostic coverage and performance for security calculations due to NC aux contact with mirror contact function compliant with EN6047-4-1 Annex F 
• Smallest Schaltbau contactor for 350A Thermal current, complete plug-and-play capability 

“Through meticulous engineering and a tireless pursuit of excellence, the C303 series exemplifies our commitment to delivering cutting-edge solutions,” said Steffen Munz, CEO, Schaltbau Group. “This contactor series sets new standards for performance and efficiency in bidirectional DC applications. We are proud to introduce a product series that not only pushes the boundaries of innovation but also empowers our customers to achieve their electrification goals with confidence.” 

With ultra-low contact resistance just above 100 µΩ, power loss is minimized, optimizing system efficiency; and with reduced contact warming, measuring 2 to 3 times lower than competitors, the series boasts superior thermal management capabilities. This translates to enhanced reliability and longevity, even in challenging conditions, thanks to optimized contact forces and advanced contact pills. 

Designed for high inrush currents or capacitances, C303 contactors have a making capacity of 2,000 amps. Continuously carrying up to 350 amps, they withstand short-circuit currents of up to 4,000 amperes for 20 milliseconds, staying fully functional with no contact welding – setting new standards for functionality in short time currents. Full bidirectionality ensures seamless disconnection of high-output circuits, up to 1,200 amps/850 volts, regardless of current direction. 
 

The well-designed coil drive ensures rapid switch-on times, enhancing system responsiveness and efficiency. Additionally, the use of AgSnO2 contact tips minimizes fire or explosion risks, ensuring operational safety. Finally, offering versatile auxiliary contact options—NC, NO, and CO—the C303 series is compatible with various system configurations. High diagnostic coverage and compliance with EN6047-4-1 Annex F ensure exceptional performance levels for security calculations. 
 

As part of Schaltbau’s new brand Eddicy, the C303 contactor series provides unparalleled performance and reassurance in critical applications. 

“Schaltbau has always been synonymous with innovation, high-quality and reliability,” says CEO Steffen Munz, CEO, Schaltbau. “The launch of Eddicy is the latest testament that we are not just adapting to change. We are driving it. Leveraging our expertise in railway applications, we are transforming ourselves into a technology leader for DC power in the energy and e-mobility sectors as well. This marks a pivotal moment in our history, as we continue to innovate and set the benchmark for excellence in our industry.” 

Eddicy products are designed to unlock the full potential of electrification for a more sustainable, carbon-free future as they reliable switch, connect, control, and protect DC applications in energy and e-mobility such as charging stations, energy storage systems, and electric vehicles of all kinds. DC applications and products that switch, protect, and secure high-voltage power play a crucial role in the transformation to a climate-neutral economy.

The launch of Eddicy is part of a broader corporate brand refresh at Schaltbau that includes modernized logos, a redesigned website, and newly defined corporate mission, vision and values that reflect the strategic focus of the organization. 

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 its sub-brand SPII.

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