Ultra-fast EV truck charger hits 1 MW using just 500 kW grid power

German researchers from Fraunhofer ISE and partners have developed an ultra-fast electric vehicle (EV) truck charging system capable of delivering over 1 megawatt (MW) of power with a record efficiency of 99.26%. The system, created under the HV-MELA-BAT project, integrates ultra-efficient power electronics, including a modular, galvanically isolated DC/DC converter rated at 250 kW each, combined to reach the megawatt level. A key innovation is the use of a buffer storage unit made from second-life passenger car batteries, which allows the charger to supply 1 MW of power while drawing only 500 kW from the grid, thereby reducing grid load and enabling rapid charging of heavy-duty electric trucks and buses. The system supports the new Megawatt Charging System (MCS) standard while maintaining backward compatibility with the existing Combined Charging System (CCS). It features a robust high-current contact interface designed to safely handle extreme voltages and charging loads. Additionally,