Fast EV charging
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High-power solutions for fast EV charging
Along with the ever-growing number of electric vehicles on the market and pressure from governments to reduce vehicle emissions to zero latest by 2050, there is a strong need for more efficient charging solutions. As various consumer studies show, the acceptance of electromobility very much depends on the availability and duration of the charging process, high-power DC charging stations are the answer to these market requirements. Already today, a typical EV can charge about 80% of its battery capacity in less than 10 minutes. This is comparable to refueling a conventional car with internal combustion engine.
As the market leader in power electronics, Infineon helps you to bring energy-efficient DC fast charging designs to life. Benefit from one of the most comprehensive, ready-to-implement one-stop product and design portfolios on the market that covers the entire product range from power conversion, microcontrollers, security, auxiliary power supply, and communication.
Advanced solutions from control to sensing to next level security and connectivity
For DC EV charging designs up to 150 kW, Infineon’s discrete products offer the best price/performance ratio. These include our 600 V CoolMOS™ SJ MOSFET P7 and CFD7 families, 650 V IGBT TRENCHSTOP™ 5 and 1200 V CoolSiC™ MOSFET. Our CoolMOS™ and CoolSiC™ MOSFETs 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. Our portfolio of high voltage switches is complimented by 650 V and 1200 V CoolSiC™ Schottky diodes. Since every switch needs a driver, and every driver needs to be controlled, we also offer the matching EiceDRIVER™ gate driver as well as XMC™ and AURIX™ microcontrollers for EV charging designs. OPTIGA™ products complete the portfolio and ensure data protection and security. Chargers in the power range above 50 kW are typically built with IGBTs CoolSiC™ MOSFETs and diode power modules, e.g. CoolSiC™ Easy Modules, IGBT EconoPACK™ and the IGBT EconoDUAL™ family. Charger piles with a capacity of more than 100kW are usually built in a modular approach with stacked sub-units. Already today, these sub-units have reached a capacity of 20-50 kW each and will go beyond this in future designs.
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.
Typically, a high-power DC charger converts an incoming three-phase AC power into the DC voltage required by the vehicle’s battery. A data transmission channel is required to exchange information about the vehicle and the battery's state of charge. Finally, vehicle information and owner data are communicated through a secure data channel for billing purposes.
The three primary concerns in DC fast charger architecture are minimizing cooling efforts, providing high power density and reducing the overall size and cost of the system. High power density requires forced air cooling, which is standard today. However, the next generation of charging solutions will require liquid cooling driven by the system power density increase. Compact designs must consider higher switching speeds, in the range of 32 to 100 kHz, to reduce the size of magnetic components.
The strategies to achieve zero emissions latest by 2050 in most major cities worldwide relies in part on greater EV usage and therefore 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 EV models 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. Due to space limitations in urban area, future charging needs cannot be satisfied by private installations. Therefore, public charger will gain more and more importance to increase usability of urban eMobility. Finally, as battery manufacturers optimize their cost structures and economies of scale, electric vehicles have never been more attractive to purchase.
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 process of charging an electric vehicle at a charging point must allow for the identification, authentication and safeguarding of information that passes between the charger, the vehicle and the backend infrastructure. This requires cryptography that protects both the charging infrastructure and the vehicles that use it.
Part of the ISO 15118 international standard is the concept of Plug & Charge. It allows vehicles to be charged without having to present a special charging card at the charging station This provides a secured and convenient way to charge an electric vehicle that includes both wired and wireless charging technologies based on AC and DC subsystems. At its core, Plug & Charge is intended to ensure confidentiality, data integrity and authenticity, which is achieved through symmetric and asymmetric cryptography algorithms defined in ISO 15118.
To implement this standard, a tamper-proof microcontroller such as Infineon's OPTIGA™ TPM SLI 9670 Trusted Platform Module can be used, which is a standardized component according to the Trusted Computing Group (TCG) TPM standard. The TPM plays an essential role in securing the Plug & Charge financial transaction by protecting the authenticity of the entities involved, the integrity of the data exchanged, and the confidentiality of sensitive information.
In addition, the OPTIGA™ TPM SLI 9670 is also used for the platform protection and the secured data transmission between a server backend, the charging station and the EV. This is required to secure remote functionalities such as firmware updates, maintenance and management of the charging infrastructure devices.
Parametric Product Finders
Webinar: Fast DC EV charging with CoolSiC™ from Infineon
As electromobility increasingly becomes part of our daily lives, the need for more efficient charging solutions is growing. Looking at the requirements and technological developments in this area, the challenge is to respond with smart and compact power conversion solutions for the charging networks of today and tomorrow. In this webinar, you will gain deeper insights into Infineon's comprehensive DC EV charging portfolio with a focus on silicon carbide and its important contribution to ultra-fast EV charging.
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 electromobility.
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.
- 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:
- 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
In this training you will:
- Identify the challenges posed by traction inverter applications in terms of system requirements, size, cost and time.
- Describe EasyPACK™ 2B EDT2’s distinctive features and explain how Infineon is able to meet customer needs. Especially in relation to quality and ramp-up capability.