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As the Electrical Vehicle (EV) industry has been booming nowadays, “Charging” has been discussed a lot and the hot topic is always about how to supply electricity to these vehicles in a faster and greener way. When we look at the supply process from electricity source to EV battery, it could be easily separated into three stages which are charging station, cable, and on-board charger. In this article, we will discuss the charging concepts and the power structure.
The Charging Station and the On-Board Charger
1. The charging station:
The power source comes from the charging stations and the charging stations provide the Alternate Current (AC) or the Direct Current (DC) source. There are three levels of charging stations on the market now:
Level 1: AC (120V) source charging. This is the slowest charging option and suitable for installing at residential areas for long hours of charging during the night.
Level 2: AC (230V) source charging. This is a faster charging method compared to level 1. Most public charging stations are level 2, which provide mid-range power charging service.
Level 3: DC (200-425V) source charging. This is the fastest charging choice, which could have the EV battery fully charged within 1 hour.
2. On-board charger (OBC)
OBC is built inside the vehicle to convert suitable voltage for recharging the battery. The common OBC is to convert AC to DC which includes PFC and DC/DC stage. For DC source charging, it converts high DC voltage to the suitable voltage and directly charge the battery and prevent the power lost or distortion of power conversion from AC to DC.
The challenge of the power supply design (Charging station & OBC)
Since the charging stations are installed in the outdoor environment mostly, it faces common challenges such as the extreme changes of temperatures caused by weather and water- dust proof. Besides, the power might need to comply with:
1. Vibration requirement (OBC)
2. Voltage fluctuation and Surge requirement
3. Reliability requirement
4. Others specific requirements
Application Block diagram with Cincon’s power solution
Here are some block diagrams which are the solutions to different charging sources.
1. AC source solution:
Cincon’s AC/DC power supply has multiple features that match with the charging station requirements perfectly:
a. High efficiency up to 94.5%
b. High isolation up to 4000Vac
c. Covers input range up to 80~264Vac range
d. EMC immunity compliance with EN55032/EN55035
e. Operating temperature up to -40~85℃
|Model||Type||Input Voltage||Output Voltage||Power|
|PFC750||Half-brick PFC module||90~264Vac||390V||750W|
2. DC source solution (Fast charge)
For the HVDC source, Cincon has series of high input voltage DC/DC converters which meet the input range up to 200~425Vdc. Other features as follows:
1. 75W to 750W output power range
2. High isolation 3000Vac
3. Widest operating case temperature to -40~105℃
4. High efficiency up to 91%
5. Parallel operation available
|Model||Type||Input Voltage||Output Voltage Power||Power|
|CHB300-300S||Wall-mount||180~425V||5V, 12V, 15V,
|CHB300-300S-CMFC(D)||Chassis mount||180~425V||5V, 12V, 15V,
|CFB600-300S||Full-brick module||180~425V||12V, 24V, 48V||600W|
To meet the requirements of high reliability and performance in EV charging applications, the power supply design has to catch the needs of the market demand. Cincon has been dedicated in developing advanced power supply modules and units which could be qualified for various real applications. Contact us for your inquiries and application needs.
More information: High Input Voltage Products
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