Charged EVs | 3 design concerns for next-gen EV charging stations


Sponsored by Littelfuse

Easy methods to make tomorrow’s charging stations extra environment friendly, extremely dependable, and safer

International hybrid and electrical car adoption rely on the community of fast-charging EV stations out there. Customers don’t wish to run out of juice the place they can’t recharge their automobiles. 

Widespread adoption additionally is determined by lowering the charging time, with the aim of getting EV charging occasions as near the time it takes for a traditional fossil gas fill-up. This requirement stipulates that high-power charging stations have greater than 50 kW of charging energy, and the problem is that these kinds of quick charging stations are comparatively costlier. 

Given the rising significance of fast-charging stations, the demand for increased energy ranges, and the numerous funding to ship each, it’s essential that EV charging system designers plan for elevated effectivity, reliability, and security.

  • Effectivity. DC quick charging techniques should convert energy effectively. It’s essential to attenuate the ability conversion losses to make sure most energy supply for charging car batteries whereas lowering warmth buildup.
  • Reliability. After set up, EV charging tools should function dependably for at the very least ten years, even in very harsh outside circumstances, to make sure a suitable return on funding. 
  • Security. Above all else, consumer security is paramount. Till just lately, the general public has not had entry to energy increased than what is out there from the wall sockets of their houses. The arrival of DC charging stations has modified that, making 400 to 1,000 V DC out there. EV chargers should defend customers from the specter of electrical shock and different hazards. 
Charged EVs 3 design considerations for next gen EV charging
DC charging station and useful components that require circuit safety. 


Energy semiconductors convert AC energy into the DC energy wanted to recharge a car’s batteries. The ability semiconductor gadget controls the cost by switching to match the cost stage to what the car battery requires, which naturally incurs energy losses within the type of warmth. That warmth can create engineering challenges in an EV charging utility. 

That’s why utilizing superior units primarily based on SiC and GaN applied sciences in energy conversion is smart; in comparison with silicon units, they supply ultra-fast switching that leads to decrease energy losses. 

SiC MOSFETs mixing excessive working voltages and quick switching speeds at the moment are out there, a mixture not discovered with conventional energy transistors. Vehicle charging functions should function at excessive junction temperatures and have low gate resistance, low output capacitance, low gate cost, and ultra-low on-resistance. Charging station designers desire units that supply excessive energy density and cut back filter elements’ dimension and weight, lowering price and area necessities.


DC charging stations are costly in comparison with cellular units engineered for a 3 to five-year lifetime, so the end-users want them to final for greater than ten years to get a suitable return on funding. Semiconductor content material prices vary from $350 in AC chargers to over $3,500 in a 350-kW charging system. That’s the reason correct circuit safety is so essential: it can maintain the funding working reliably for a extra prolonged interval. 

Semiconductors are usually fabricated from silicon or silicon carbide and have low thermal face up to capability, thus making them very delicate to electrical threats. They should be shielded from overcurrent by fuses. 

Whereas standard fuses can defend most units, specialised high-speed DC fuses are required to guard the MOSFETs, IGBTs, thyristors, and diodes utilized in energy converters (rectifiers, inverters, and so on.) These fuses are engineered with a particular time-current attribute and function in a short time in comparison with conventional AC enter fuses. 

Overvoltage is one other risk to delicate semiconductors. For instance, an EV charger close to an industrial facility that makes use of massive motors can expertise voltage surges within the energy provide attributable to the on and off switching of these motors. Moreover, lightning strikes close to the charging station end in electromagnetic power that will induce a voltage surge on the neighborhood’s energy strains that would propagate into the charger by way of the AC energy enter strains. To soak up that power, the charging station should use overvoltage safety to stop harm to the delicate electronics that make the charger work.


An EV charging station’s two greatest security threats are electrical shock and overcurrent. Electrical shock is normally the results of a floor fault. 

Electrical Shock
A floor fault is an unintended contact between an energized conductor and floor or the tools body. Insulation breakdown is the everyday wrongdoer. Additionally, mud and moisture could cause unintended pathways for electrical energy. Moist and dusty environments, similar to these discovered round outside tools require diligence in design. 

Charged EVs 3 design considerations for next gen EV charging
TVS Diodes (just like the Littelfuse SMF Floor-Mounted TVS Sequence) are designed particularly to guard delicate digital tools from voltage transients induced by lightning and different transient voltage occasions.

AC ground-fault safety is required on the enter aspect of the design to guard elements from harm and customers from electrical shock ought to the tools body or housing change into energized. A ground-fault safety gadget makes use of a present transformer on the section conductors to make sure that all present coming from the supply returns on those self same conductors, or it reads the present within the connection between the transformer impartial and floor. A floor fault wherever within the system will return present by way of this path. 

Equally, ground-fault safety is required on the output aspect, in order that when a shopper picks up a nozzle able to 1,000 V, the deal with or the body isn’t energized. A DC ground-fault monitor is put in on the output aspect to detect any earth leakage and shut off energy instantly. Because the output aspect isn’t grounded, the ground-fault monitor is determined by a ground-reference module between the 2 buses to determine a impartial level, which is used as a reference to detect low-level floor faults. 


By their nature, car charging stations are related to an influence provide that has excessive out there fault present. Electrical faults, together with people who begin floor faults, can draw excessive present that may be very harmful, damaging elements, twisting bus bars, beginning fires, and even trigger an arc-flash incident—a type of explosion that would injure or kill anybody standing close by. 

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Varistors are designed for functions requiring excessive peak surge present rankings and excessive power absorption functionality (see the Littelfuse UltraMOV Steel Oxide Varistor Sequence).

Choose fuses primarily based on their interrupting capability, their ranking primarily based on regular working present, and their time-current curve traits. “Present limiting fuses” function shortly within the occasion of a high-value overcurrent, which limits peak let-through present. 

Except interrupted shortly, even reasonable overcurrents can overheat system elements, damaging insulation and conductors. Nonetheless, the worst harm can be to the numerous digital elements, that are vulnerable to low-value overcurrents.

Make Circuit Safety a Forethought, Not an Afterthought, in DC Charging Stations Design 

Right this moment’s circuit safety units embody many alternative applied sciences, every with particular utility options in thoughts. Whereas many units may go, choosing a element with the perfect expertise for the appliance is healthier. In a DC charging system, high-power Transient Voltage Suppressor (TVS) diodes or steel oxide varistors (MOVs) usually supply the most effective suppression kind. Other forms of protectors—similar to gasoline discharge tubes (GDTs),  safety thyristors, and multi-layered varistors (MLVs) or mixtures of suppression units — are sometimes specified.  

1662566756 258 Charged EVs 3 design considerations for next gen EV charging
SiC-based MOSFETs from Littelfuse are optimized for prime energy, Low resistance, and low energy conversion losses not out there with conventional silicon units.

When defending delicate circuits, it’s important to know the time a transient suppressor requires to start functioning. For instance, if the suppressor is slow-acting and a fast-rising transient seems within the system, the voltage throughout the protected load can rise and trigger extreme harm earlier than the suppression can kick in.  

Obtain the Littelfuse Supercharged Options for EV Charging Stations Information from TTI to be taught extra. 

Discover your Littelfuse eMobility Product Options from TTI. 

Sponsored by Littelfuse


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