MCS brings unique challenges to the EV charging space. The most popular way to build CCS chargers these days is to just use air cooled power module concept, where air blows directly on power transformers, SMD components and magnetics. This approach was borrowed from server power supplies - but unlike server rooms, the outdoor environment doesn’t have dry, clean air with no dust. Deploying MW level charging requires more reliable designs, capable of withstanding the elements. The best way to achieve this is to use truly environmentally sealed power modules, where the outsize air doesn’t need to interact with sensitive power electronics.
ADVANTICS power modules can be assembled within fully dust-proof and moisture-proof enclosures. Both cooling concepts (air-cooled heatsinks and watercooled blocks) can be used - which means it is possible to build charging systems intended even for coastal operation, with high salt content in the air. This is especially important for electric ferries and ships - which needs to be installed directly next to the pier.
The following diagram shows a straight-forward 100kW building block, from which multi-MW systems can be built. The block starts with a mains filter with integrated AC precharge, then a synchronous PFC (with THDi of less than 5%). This is followed by a DC/DC with reinforced isolation. There are two independent isolated converters, with their inputs being in parallel, and outputs in series, to provide voltage doubling. Each isolated DC/DC has a follow-up step down converter to provide voltage and current control.
If output contactors with series/parallel reconnection are added, the building block will have effectively twice the power for low voltage systems, dramatically expanding the power envelope.
The proposed system would look like this:
Example calculations of power per block:
Compact and versatile, it supports EV charging protocols like MCS, CCS AC/DC, DIN SPEC 70121, ISO15118-2/-20, NACS, and CHAdeMO. With bidirectional power transfer, Plug and Charge (coming soon), OCPP support, OTA updates, and its flexible mounting options, the SPCC is ideal for charging stations and wallboxes.
Electric Vehicle onboard charge controller for DC and AC charging standards. Aimed to be embedded in any kind of electric vehicle using conductive charging. Enables advanced features such as bidirectional charging using latest standards and Plug’n’Charge.
This power module fits any application where you need bidirectional AC/DC rectification, DC/DC conversion or DC/AC generation, with up to 99% efficiency in a wide operating range.
This bidirectional DC/DC transformer operates at very high frequencies allowing it to reach an impressively high power density. It is perfect to add isolation to your application, or even as a transparent add-on in preexisting topologies, while keeping bidirectionality and high efficiency.
Optimized to be the last power conversion stage for battery charging, it includes galvanic isolation, insulation fault measurement and fast output discharge circuit. With a maximum efficiency of 98%.
