One Stop Shop for EV Charger Control

One Stop Shop for EV Charger Control

Demand for electric vehicles is on the increase, but the market is ultimately going to be limited by the volume of charge stations available to the public. Electric Vehicle charge stations whilst themselves being very large power supplies, also contain a number of sub-circuits with require equally reliable and durable power conversion products. In this article, we take a close look at the types of charger on the market today, and the requirements for localised power within the overall system.

A rapidly growing market

Investments around the world mean that the global EV charging station market is expected to grow from $17.59 billion in 2021 to $111.90 billion by 2028, representing a CAGR of 30.26% in this period, according to market analyst firm, Fortune Business Insights.

In EV charging stations, there are two main parts: the main power trains and control, communication and surveillance systems. Both use auxiliary power converters ranging from 1W-200W.   

EV charger types

There are currently three levels of EV chargers today. The first is AC Level 1. This is a simple but slow charge direct from domestic mains (typically up to 3.7kW). For typical Level 1 charging equipment, Mornsun’s LS-R3 series of compact, open frame, ac-dc power supplies, is ideal. The series covers 1W to 15W and models have a wide input range of 85 to 305Vac. The operating temperature range is -40°C to +85°C for the automotive environment. It is also designed to be compact, with a flexible layout making it ideally suited to the often confined spaces available in charging stations.

For AC Level 2 charging, typically a domestic (daytime or night-time) installation up to 22kW, with communication control, Mornsun can provide the ultra-compact LD-R2 compact, open frame ad-dc power supplies. These high quality power supplies are rated from 3W to 90W. They have a universal wide input voltage of 85-305Vac and a wide operating temperature range of -40°C to +85°C. They are for Overvoltage Category III (OVC III) fixed installation applications and have reinforced isolation up to 4.3kVac.

The third category is DC Fast Charge (DCFC). This is delivered by roadside charge stations which by nature means that have to be fast charging, delivering up to 400kW.

For this category, Mornsun’s LM / LMF series enclosed ac-dc converters are available. They have a wide input voltage of 85-305Vac and an operating temperature range of -30°C to +75°C and efficiency up to 92%, making them ideal for charging piles in DCFC charging stations.

AC Level 2 and DCFC systems have multiple auxiliary power requirements which need to be considered when designing the power system in the charger. For example, the main charger module uses IGBT/SiC transistor drivers, which will require drive voltages. The control systems will run from 3V3 or 5V microcontrollers, and communications systems require  +/-12V, contactors 12V or 24V, while cooling systems and display/interface systems both require 12/24V.

Design summary

Here is a design checklist:

• All power components should be reliable, meet environmental requirements and have a high MTBF.
• When choosing auxiliary power components, to bear in mind compatibility – Europe, the US and Japan operate with different ac supplies.
• Consider voltage fluctuations; input voltages can easily exceed 264Vac, which can be accommodated by power devices with inputs of 305Vac.
• Components should have excellent radiated and EM susceptibility characteristics to avoid affecting other components.  All power components selected should also have good surge and transient responses and for outdoor enclosures, subject to high levels of moisture ingress, key components should be potted or conformally coated.
• It almost goes without saying that it is important to design these systems with low standby power to minimise energy consumption.

Here at Relec we are a happy to offer free of charge samples, many of which we have in stock for immediate delivery.  We will also offer full technical support to help integrate the converters into your design as well as finding solutions for other aspects of your power topology…

GET IN TOUCH TODAY – 01929 555700

Here at Relec Electronics, we have worked closely with our key suppliers for over 40 years. We specialise in many industries, including; automotive, industrial, transportation, instrumentation & defence. We have a team of dedicated engineers ready to support you throughout the design process. We also carry stock of all standard modules and accessories for next day delivery.

Let’s make this easy and call us today.

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