Megawatt Charging System (MCS): Powering the Future of Heavy-Duty EVs

As heavy-duty vehicles increasingly transition to electric powertrains, the pressure on charging infrastructure is rising at an unprecedented rate. Although the Combined Charging System (CCS) can theoretically deliver up to 500 kW, this level of power falls short for trucks and other heavy-duty vehicles equipped with batteries in the 500–1000 kWh range. To bridge this gap, the Megawatt Charging System (MCS) has emerged as a next-generation standard, capable of delivering charging power of up to 3.75 megawatts, equivalent to 3000 amps at 1250 volts DC.
 
Core Technical Characteristics of MCS
The MCS standard is engineered specifically to meet the extreme power demands of heavy-duty electric mobility:

Thanks to these capabilities, MCS can replenish a 1000 kWh battery in well under half an hour—an essential requirement for the cost-effective operation of electric trucks and other high-utilization vehicles.
 
Industry Sectors and Use Cases
The rollout of MCS significantly expands the scope of electrification for applications with exceptionally high energy requirements. Sectors that depend on large batteries, minimal downtime, and continuous availability stand to gain the most. Key use cases include:

 
Technical Barriers and Engineering Complexity
Deploying megawatt-level charging introduces challenges that extend well beyond conventional EV charging systems. One of the most demanding issues is thermal control. Currents approaching 3000 amps generate substantial heat, which can compromise efficiency and safety if not properly managed. MCS addresses this through actively liquid-cooled cables and connectors, ensuring reliable operation even during prolonged high-power charging sessions.

Electrical safety is another critical consideration. Operating at voltages up to 1250 V significantly raises the bar for insulation, arc fault detection, and overvoltage protection. The MCS architecture incorporates layered safety measures, including galvanic isolation, automated mechanical locking, and continuous real-time monitoring throughout the charging process.

The communication framework also represents a major shift. MCS replaces PLC-based signaling with automotive Ethernet technology, enabling stable, low-latency communication while maintaining electromagnetic compatibility at extreme power levels. This is particularly important for precise charging control, authentication, and system diagnostics.

Finally, physical handling presents practical challenges. The size and weight of MCS cables and connectors make manual operation impractical in many scenarios. As a result, robotic and automated charging solutions are being explored to improve ergonomics, standardization, and operational efficiency—especially for fleet and logistics applications.
 
Infrastructure and Grid Integration Considerations
Megawatt charging places equally demanding requirements on the supporting infrastructure and power grid. With individual charging points drawing up to 3.75 MW, direct access to the medium-voltage grid is typically required. Conventional low-voltage connections used by standard fast chargers are insufficient, necessitating dedicated transformers, switchgear, and protection equipment.

Energy and load management becomes a central factor in ensuring both grid stability and economic operation. Intelligent control systems are needed to schedule charging, prioritize vehicles, and coordinate power delivery. These systems can also integrate on-site energy sources such as solar generation or stationary battery storage. In high-traffic locations—such as logistics hubs or highway charging corridors—dynamic load balancing is essential to prevent grid congestion.

Designing for scalability is another priority. Charging sites must be capable of expanding as demand grows, both physically and electrically. This requires close coordination between infrastructure providers, utilities, and regulatory authorities, particularly when upgrading or extending medium-voltage connections.

Equally important is standardization. Interoperability across vehicle manufacturers, charging providers, and backend systems is critical for widespread adoption. Organizations like CharIN are leading efforts to globally harmonize MCS specifications, helping ensure compatibility, reduce risk, and protect long-term investments.
 
The Road Ahead: MCS as a Catalyst for Transport Decarbonization
MCS is transitioning rapidly from concept to reality and is expected to become a cornerstone of heavy-duty transport electrification. Pilot deployments are already underway in Europe and North America, with broader commercial adoption anticipated from 2025 onward—particularly in long-haul trucking, where charging speed directly impacts operating economics.
Over time, MCS will extend beyond highways and depots into ports, airports, and industrial zones, enabling electrification across multiple transport modes. In these environments, MCS can serve as a unifying technology, supporting everything from electric trucks and vessels to automated ground vehicles.

Automation will further accelerate adoption. When combined with autonomous vehicles and robotic charging systems, MCS enables fully automated, 24/7 charging workflows—an attractive proposition for logistics operators with high vehicle utilization and tight turnaround times.

Regulatory momentum is also accelerating demand. Stricter CO₂ limits, zero-emission zones, and government incentives in the EU and other regions are driving investment in high-capacity charging infrastructure. At the same time, MCS is designed with future expansion in mind, offering a scalable platform that can support advanced capabilities such as bidirectional charging and grid-supportive energy management.

Ultimately, MCS represents far more than a new connector standard. It is a foundational technology for a cleaner, more efficient, and highly connected heavy-duty transport ecosystem.
 
How Keysight Enables the Shift to Megawatt Charging
Against this rapidly evolving backdrop, Keysight supports vehicle manufacturers, charging system developers, and component suppliers as they tackle the complexities of megawatt charging. Drawing on decades of expertise in high-power electronics, automotive validation, and energy systems, Keysight delivers end-to-end test and measurement solutions focused on safety, performance, and interoperability across the MCS value chain.

By aligning with standards such as ISO 15118-20 and actively contributing to the evolution of MCS specifications, Keysight helps ensure that emerging solutions meet both current requirements and future demands. From full charging systems to individual components, Keysight’s tools and expertise help shorten development cycles and accelerate time to market.

Key offerings include:

Through this combination of advanced technology, industry knowledge, and standards leadership, Keysight serves as a trusted partner in building a robust, scalable, and future-ready megawatt charging infrastructure for next-generation electric heavy-duty transport.

Click here to know more about the Megawatt Charging Test Solution.