Let you know the design scheme of different power electric vehicle charging piles
Latest update time：2024-11-05
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With the transformation of the global energy structure and the improvement of environmental awareness, new energy vehicles such as electric vehicles and hybrid vehicles have been widely promoted and applied worldwide. As the "gas station" of new energy vehicles, charging piles are not only a bridge connecting the power grid and electric vehicles, but also an important infrastructure for realizing smart grids, promoting the use of renewable energy, and promoting the electrification transformation of urban transportation. According to the data of the China Electric Vehicle Charging Infrastructure Promotion Alliance, from January to November 2023, the increase in charging infrastructure reached 3.054 million units, and the increase ratio of piles to vehicles was 1:2.7. The construction of charging infrastructure is gradually keeping up with the growth of new energy vehicles.
Technological innovation is becoming a key driving force for the rapid development of the charging pile industry. In order to meet the charging needs in different scenarios, this article will introduce three mainstream electric vehicle charging methods in different power ranges.
AC charging
AC charging is the most common charging method on the market, usually using a household power socket or a dedicated AC charging station. This charging method has a power range of 3.3kW (single-phase) to 22kW (three-phase), which is suitable for home and office use. Its advantages are simple equipment and low cost, but the charging time is long. For example, an 80kWh battery may take 12 hours to be fully charged.
In AC charging, as the interface between electric vehicles and the public power grid, the on-board charger (OBC) is installed inside the electric vehicle, which can convert the AC power from the power grid into the DC power required by the electric vehicle's high-voltage battery to meet the charging needs of the electric vehicle's power battery. At the same time, it can also invert the DC power of the power battery into AC power and feed it back to the power grid, realizing energy conversion between the electric vehicle's power battery and the power grid.
OBC Typical Block Diagram
OBC mainly includes three modules: EMI filter, power factor correction (PFC) stage and isolated DC-DC converter with independent primary and secondary parts. It usually adopts bridge Single Boost or full-bridge/half-bridge LLC topology to achieve efficient power conversion and stable output. The current design trend is to evolve towards higher power levels and voltages, and the design supports various voltages and power levels. For example, while supporting 11kW to 22kW power, it also needs to support higher battery voltages up to 800V.
DC charging device (DC Wallbox)
A DC Wallbox or DC charging module is a DC charging device that is usually designed as a small charging device installed on the wall. It provides a faster charging speed than AC charging. The power range of this charging method can be from 6.6kW (single phase) to 75kW (three phase), fully charging an 80kWh battery in 2 hours. The charging equipment is usually small in size, moderate in weight, and moderately priced, making it suitable for public parking lots and commercial charging stations.
When charging in direct current mode, an electric vehicle charger (EVC) is also required, but it is usually not integrated into the electric vehicle, so its design focuses on providing efficient power conversion and fast charging capabilities, while also considering compatibility with the power grid and charging safety. A typical DC EVC may use a three-phase Vienna/T-NPC PFC topology or a three-phase full-bridge PFC topology, as well as an isolated DC-DC converter of a three-level full-bridge LLC or I-NPC to achieve high efficiency and low EMI.
Typical block diagram of DC charging
DC fast charging pile
Fast DC charging stations (DCFC) are the fastest charging solution for electric vehicles, with power ranging from 30kW to 600kW. This charging method can fully charge an 80kWh battery in 15 minutes, and is suitable for highway service areas and large charging stations. Fast DC charging stations are large in size, and can achieve higher output capacity by connecting multiple charging modules in parallel. At the same time, multiple outputs are compatible with AC charging. They are more expensive but provide great convenience.
To achieve faster charging, adapt to higher electric vehicle battery voltages and improve overall power efficiency, DC fast charging piles must operate at higher voltage and power levels. At the same time, since DC fast charging piles integrate various components, including auxiliary power supplies, sensors, power management, connections and communication devices, flexible manufacturing methods are required to meet the changing charging needs of various electric vehicles. The challenge for OEM manufacturers is to design an architecture that can optimize efficiency without compromising reliability or safety.
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