The availability of chargers is the bottleneck for faster development of electric vehicles.

The entire automotive industry is investing millions of euros in the development and production of electric vehicles. The electric vehicle market is growing very rapidly in terms of vehicle sales, and the rollout of chargers is not keeping pace with market demand, particularly for vehicles that require fast charging.

While China will be the country with the fastest-growing fleet of electric vehicles by 2021, Europe is in the lead in terms of market share. Approximately 6.5 million electric vehicles (both fully electric and hybrids) were sold worldwide last year, a figure that is 109% higher than in 2020, according to the Canalys institute. This growth is also supported by the announcement of new environmental standards for 2025 and by the European Commission’s March 13, 2020 regulation regarding the conversion of internal combustion vehicles to battery-electric or fuel cell vehicles by 2035.

Buffer battery chargers enable slow charging from the grid, allowing rapid power release to the vehicle.

The deployment of charging networks and stations is thus essential in response to this strong growth in end-user demand and the continued record-breaking sales of vehicles. This approach should help mitigate the impact on existing infrastructure, particularly in terms of potential power surges with the current limited electrical grid. Batteries serve as an energy buffer, preventing voltage drops and power outages that could occur when thousands of vehicles are connected to a charging station simultaneously.

One response to this increasing demand will be high-power chargers that carry batteries. They provide a quick-to-implement solution, avoiding voltage surges on the grid and enabling fast charging for end users. Another answer to this growing demand will be high-power chargers with integrated batteries. They offer a rapid deployment solution that avoids power surges on the grid and delivers quick charging for end users. The integration of batteries and power converters—essential for transforming energy from alternating current (AC) to direct current (DC) and vice versa, as well as modifying DC voltage—addresses various challenges in installation, adaptability to the existing grid, and compatibility with the different battery voltages of customer vehicles at these charging stations.

Fig 1. Single charger

Fig 2. Multiple chargers

Fast chargers therefore require innovation across all components.

As FreeWire Technologies explains, the market now needs a comprehensive solution more than ever, one that ensures fast charging—80% of the charge delivered in 20 minutes. To achieve this, various market players must collaborate, share their expertise, challenge each other, and combine their knowledge to develop new battery technologies.

Many suppliers, such as Skeleton Technologies and Maxwell Technologies, to name a few, offer cutting-edge supercapacitors and ultracapacitors to electronics manufacturers for energy storage, meeting end-user demands.

Furthermore, given the high demand in the battery market, innovation is highly desirable in manufacturing capacities as well. This is why Northvolt has announced plans to develop a 60 GWh lithium-ion battery factory in Germany, slated for production in 2025. Similarly, Verkor, in partnership with Renault, Schneider Electric, and Arkema, has announced the construction of its first plant dedicated to producing low-carbon battery cells. Another example illustrating this need is the partnership between Total Energies, Stellantis, and Mercedes-Benz. They have established the Automotive Cells Company (ACC) and are investing in multiple battery factory projects to achieve a production capacity of at least 120 GWh by 2030.

Finally, innovation in DC-DC converters is essential, as they are becoming a key element in the overall architecture of fast-charging stations. Thus, making improvements to components (SiC, MOSFETs, diodes, power modules, GaN…), to the overall architecture, and to product integration would likely optimize cooling and increase power density beyond 25 kW/kg while reducing costs.

The team at Tame-Power, part of the company TRONICO, also plays a crucial role in this ongoing effort to meet user needs.

Tame-Power provides intelligent interfaces between energy sources and consumers, aligned with market advancements.

While Tame-Power has been an expert in power conversion and distribution modules for highly demanding markets for several years, the brand has recently developed a DC-DC converter dedicated to fast charger applications. This intelligent solution, essential for powering end-user vehicles from the battery voltage, is based on:

• Proven expertise and know-how through various developments for automotive (on-road and off-road) and aerospace applications, to name the primary sectors;
• The integration of innovative features into existing products. Peak power is automatically adjustable based on the operating point and voltages, allowing optimal use of products and electronic components. In other words, with Tame-Power’s solution, you always have maximum power available;
• The capability to reach up to 120 kW, and with possible parallel connections, up to 240 kW or 360 kW, depending on needs.

Thanks to its capacity for customization at all stages of product development, Tame-Power is pleased to review and consider any specific requests for adaptation to the unique constraints of fast chargers: packaging and dimensions, coupling of multiple units, mechanical and battery characteristics, and more.