Fast EV charging
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From power and control to sensor and security
As e-mobility increasingly becomes part of daily life, there is a growing need for more efficient charging solutions. Fast electric vehicle (EV) charging stations equipped with powerful DC chargers are currently the answer. DC EV chargers are an attractive choice because they allow much faster charging than the standard AC EV ones that many EV owners have at home. Today, a DC charger with 150 kW can put a 200 km charge on an EV in around just 15 minutes. As fast charging and battery technologies continue to evolve and improve in the near future, experts anticipate the charging time to drop even further.
The fast charging market
Some key driving forces are shaping and advancing the EV charging market today. One is stricter government regulation of CO2 emissions. The target to achieve zero emissions by 2050 in most major cities worldwide relies in part on greater EV usage and better fast charging infrastructure. Certainly the high pollution index in cities, detrimental to inhabitants’ health and quality of life, is a motivation to reach this target. Zero or low emission mobility can help stem the prevalence of air pollution related health problems, such as cardiovascular disease and asthma.
The good news: by 2025 over 100 new EVs are set to launch on the market. This step in the direction of improved urban air quality adds pressure to develop and implement the charging infrastructure required to accommodate additional EVs on the road. Finally, as battery manufacturers optimize their cost structures and economies of scale, EV battery costs are decreasing. The result: electric vehicles have never been more attractive to purchase.
Our expertise, your benefits
With a one-stop shop of high-quality components and solutions, and complete application and technology know-how, Infineon enables you to overcome all fast EV charging design challenges. Our broad portfolio covers power ranges from kilowatt to megawatt, and includes power semiconductors, microcontrollers, gate drivers and authentication solutions. No other company offers a comparable selection from one source, a difference you benefit from with Infineon products and solutions. Use our components to achieve leading power density and best-in-class efficiency in your DC EV charging designs.
The full spectrum of complete EV charger solutions
As the market leader in power electronics, at Infineon we help you bring energy-efficient DC fast charging designs to life. Our CoolMOS? and CoolSiC? MOSFETs are ideal in a wide range of DC EV fast charging designs. Their matchless advantages include high frequency operation, high power density and reduced switching losses, allowing you to reach high levels of efficiency in any battery charging system.
Fast DC charger architecture
Typically, a high-power DC charger design converts an incoming 3-phase AC supply, using an AC-DC and DC-DC convertor, to the DC voltage the vehicle being charged requires. A channel for data transfer is also included to provide information about the vehicle and the battery’s charging status. Vehicle information and owner data are covered by one final element: a secure data channel for billing purposes.
The three primary concerns in DC fast charger architecture are how to minimize the cooling effort, deliver high power density, and reduce overall system size. High power density requires forced air cooling, a standard today. However, next generation charging solutions are exploring the potential of liquid cooling solutions. Compact designs must consider higher switching speeds, in the range of 32 to 100 kHz, to reduce the size of magnetic components.
Getting rid of plugs and cables with wireless power transfer is a demand that is met by wireless charging systems. This inductive charging allows vehicles to be charged by means of energy passed from a coil in the ground of a parking space to a coil integrated into the vehicle.
Characteristics of Wireless Power Transfer:
- Power Class: 3.7 kW, 7.7 kW, 11 kW
- Static WPT: Charge while the vehicle is not in motion
- Dynamic WPT: Charge while the vehicle is moving along the WPT enabled roadway
- DC/DC conversion inside the vehicle to adapt the input voltage to the converter
Explore the system diagram of a Wireless Power Transfer:
Different power-conversion topologies can be applied to build a DC-DC-stage. The resonant topologies are often preferred since these reduce switching losses. The DC-DC-Stage is installed in the car to align output voltage and battery requirements.
Wireless Power Transfer Units are usually built using discrete solutions CoolSiC? MOSFET, CoolSiC? diodes, and CoolMOS?. Since every switch needs a driver, and every driver needs to be controlled, we offer the right EiceDRIVER? gate driver ICs as well as XMC? Microcontroller. With our current sensor solutions XENSIV? we can enable small and accurate current sensing. OPTIGA? products round out the offer, ensuring data protection and security.
The advent of large battery capacity being spread across countries has given rise to a range of forward-thinking concepts, integrating these power sources into our daily power needs. Leveraging these as part of a solar-power strategy with homes and commercial buildings using renewable energy sources to charge EVs while making the power available again in the event of power outages or to flatten peak demand. This Vehicle-to-Building (V2B) approach is stretched even further to consider power needs at a national level, leveling out power demands in conjunction with a broader move to renewable energy with Vehicle-to-Grid (V2G) implementations. V2B and V2G support behind-the-meter cases in energy storage applications and need to provide efficient AC/DC conversion. Still, they must additionally perform DC/AC conversion to feed back into the grid. Charging standards reflect both the needs of V2B and V2G.
Characteristics of Bidirectional Charging:
Up to 22 kW (typical 7 kW)
Input AC/DC Stage
Output DC/DC Stage
Output Voltage Range
V2B and V2G Units are usually built using discrete solutions CoolSiC? MOSFET and CoolMOS? MOSFET. Since every switch needs a driver, and every driver needs to be controlled, we offer the right EiceDRIVER? gate driver ICs and XMC? microcontroller. With our current sensor solutions XENSIV? we can enable small and accurate current sensing. OPTIGA? products round out the offer, ensuring data protection and security.
For secured payment
When a user pays to fast charge an EV, they need peace of mind that their personal information doesn’t fall into the wrong hands. Our discrete security controller OPTIGA? TPM2.0 enables secured data transmission between a server backend and the EV, while also safeguarding firmware updates for remote maintenance on an EV charging station.
By combining a security controller such as OPTIGA? TPM with OPTIGA? TRUST B or Trust E authentication chips, it’s also possible to authenticate component modules in an EV charger as original parts. No other company is able to offer such a wide selection of high performance products in terms of power, control, sensor and security, a difference you benefit from every time you select Infineon products.
Promoting a global standard
Infineon is part of the international Charging Interface Initiative e.V. (CharIN). CharIN’s goal is to develop, establish and promote a global charging system standard for all kinds of battery-powered electric vehicles.
Podcast4Engineers #1: Electric vehicle charging on the rise
The first episode of our new podcast series introduces you to the topic of charging electric vehicles: In particular, what scenarios are available for charging, what does this mean for the respective topologies and how can designers deal with it? Our expert has all the answers and gives you an exciting insight into the beginnings of electric mobility.
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EV charging - Detailed Information (Electronica)
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Do you want to know the various topologies you can find in this power conversion stage and their top-level working principle? Get to know the basic concepts of passive and two-level active rectification methods.
With the growing market of electrical vehicles, the industry has put forward more requirements for the performance of charging piles. This e-learning will show you that the emergence of CoolSiC? MOSFETs has improved the charging pile industry to make the EV charger smaller, faster and with higher efficiency.
In this training you will:
- Understand what EV DC charging is and what the specifications of a charger module are
- Know the replacement steps from CFD2 to CFD7 or CSFD in LLC topologies to an EV charging module
- Get to know how AURIXTM is able to answer the needs of the electric vehicle market
- Recognize and explore how AURIX? TC3xx addresses key electric vehicle challenges, and understand the main features of the AURIX? TC3xx microcontroller
In this training you will:
- Understand what an HVAC system is and how it works in electrical vehicles
- Know the IGBT market, why they are a preferred customer choice for e-Mobility and what Infineon has to offer to this field
In this video, you will:
- Understand how Infineon’s power semiconductor module portfolio is a solution for the main challenges of the electric vehicle industry
- Know Infineon’s general value drivers as well as recent success stories on the electromobility market
In this training you will:
- Be familiar with silicon carbide MOSFET structures and their characteristics
- Get to know Infineon's CoolSiC? MOSFET, its features, its improvements over a typical trench MOS and how it performs against its competitors
In this training you will:
- Get to know Infineon’s IPOSIM tool, specifically for an automotive electric vehicle inverter
- Discover the steps involved in simulating different parameters and comparing the results of different Infineon products to see which is the best fit for your application
- Get to know why systems require frequent updates, how this is done and how automotive systems try to ensure their security when they are updated
- Learn how AURIX? families of microcontrollers support over-the-air software updates
In this training you will:
- Understand how HybridPACK? DC6i can meet the challenges posed by traction inverter applications in terms of system requirements, size, cost and time
- Discover HybridPACK?’s DC6i distinctive features, namely the EDT2 and PressFIT? technology