Development of a Megawatt Charging Capable Test Platform

Vehicle recharge time is a key barrier to widespread adoption of battery electric trucks, where megawatt class charging could be used to achieve refueling times comparable to internal combustion vehicles. This work presents the design and validation of a megawatt-capable rechargeable energy storage system (144 kWh, 40P384S) together with a physics-based modeling framework for safe 1 MW operation. The pack architecture is reconfigurable, enabling nominal 750 V (80P192S) propulsion mode as well as 1125 V and 1500 V charging modes compatible with the Megawatt Charging System (MCS). An equivalent circuit model is developed to relate cell-level parameters to pack-level power, heat generation, and temperature rise, providing guidance on feasible charge profiles and thermal limits. A Simulink-based digital twin of the reconfigurable pack is then used to analyze sensitivity to current sensor mismatch and to verify protection logic for multiple bus voltage configurations. Finally, pack tests up to 1 MW confirm the model-predicted operating envelope and illustrate practical constraints imposed by charger voltage and pack resistance. The combined hardware and modeling approach provides a reusable platform for studying extreme fast charging of medium- and heavy-duty BEV packs-class charging -capable rechargeable energy storage system (144 kWh, 40P384S) together with a physics-based modeling framework for safe 1 MW operation. The pack architecture is reconfigurable, enabling nominal 750 V (80P192S) propulsion mode as well as 1125 V and 1500 V charging modes compatible with the Megawatt Charging System (MCS). An equivalent-circuit model is developed to relate cell-level parameters to pack-level power, heat generation, and temperature rise, providing guidance on feasible charge profiles and thermal limits. A Simulink-based digital twin of the reconfigurable pack is then used to analyze sensitivity to current–sensor mismatch and to verify protection logic for multiple bus-voltage configurations. Finally, pack tests up to 1 MW confirm the model-predicted operating envelope and illustrate practical constraints imposed by charger voltage and pack resistance. The combined hardware and modeling approach provides a reusable platform for studying extreme fast charging of medium- and heavy-duty BEV packs.