The core component modules of electric vehicle DC EV charging include the EV charging module, control module, power module, etc. Among them, the charging module is the heart of DC EV charging. Why? The reason is simple, the charging module accounts for about 50% of the cost of the entire EV charging pile.
The function of the charging module is to convert the three-phase AC power in the power grid into DC power that can be used to charge electric vehicles. It is the basic unit for power conversion such as rectification, inversion, and filtering.
EV Charging Module Technical Parameters
Model: 750kW50A
AC Input: 260~530V/32A
DC Output: 200~750V/0-50A
Power： 20KW
Dimension: 84mm (H) x 226mm (W) x 395mm (D)
Weight: ≤11kg
Working principle of the EV charging module
It can be divided into two main stages: AC input and DC output
AC input stage:
The DC charging pile first inputs AC power from the power grid into the transformer. The transformer adjusts the input voltage to a level suitable for subsequent circuit processing by transforming the voltage level. Next, the input current is rectified by the rectifier to convert the AC power into DC power. The rectifier usually adopts a rectifier bridge circuit, which is composed of a series of diodes to convert the AC signal into a unidirectional DC signal.
DC output stage:
After rectification, the DC power is filtered through a filter to remove any residual AC components. The DC signal then passes through a DC-DC converter to adjust the voltage and current to meet the changing needs of the electric vehicle. Finally, the DC power is transmitted to the battery for charging through the charging plug connected to the electric vehicle.
EV Charging module features
EV Charging modules generally have multiple input and output options. Users can also repeatedly stack or cross-stack to form a building block combination power supply to achieve multi-channel input and output.
Common power modules on the market include 15KW, 20KW, 30KW, and 40KW. By stacking, they can achieve higher power output, thereby shortening the charging time and realizing fast charging of electric vehicles.
In addition, power modules can also be widely used in various fields of social production and life such as aerospace, locomotives and ships, military weapons, power generation and distribution, post and telecommunications, metallurgy and mining, automatic control, household appliances, instruments and meters, and scientific research experiments.
Why do EV charging modules use a building block combination?
1. The shell of a single independent power module has a trinity structure of heat sink, radiator, and shell, which realizes the best cooling method for module power supply and enables the power module to achieve good heat dissipation when working.
2. Flexible design. When designing or changing a higher-power product, you only need to convert or connect the appropriate power module.
3. Convenient maintenance. A power module is equivalent to an independent charging unit. When the charging system finds that a power module has failed, we only need to replace it without affecting other modules.
Causes of EV charging module failure
The charging module may encounter six common faults during use, namely, module protection, module failure, uneven current, communication interruption, half-load output, and a voltage output that cannot reach the set voltage.
1. Charging module protection
Overvoltage, under voltage, and overtemperature of the charging module AC input will cause charging module protection. Please confirm according to the fault code.
Poor ventilation performance of the cabinet or dust blockage of the vents due to long-term use may cause overheating protection of the charging module.
Excessive ambient temperature will also cause overheating protection of the charging module.
2. Charging module failure
The output voltage of the charging module is too high or the IGBT is overcurrent, which will cause module failure. It is required to disconnect the module from the AC and then restart it to restore the module to normal.
Unreasonable voltage adjustment may cause the output of the module charging module to be overvoltage. In this case, it is necessary to turn off the power and adjust the voltage adjustment potentiometer counterclockwise to the minimum (a slight click sound can be heard when the potentiometer is adjusted to the minimum), and then re-adjust the output voltage of the module.
3. EV Charging module communication interruption
The wrong address setting of the charging module will cause the charging module communication interruption. Setting the same address for two different charging modules will also cause the monitoring module communication interruption.
Charging module type setting (stepped current limiting and stepless current flow) will cause the monitoring module communication interruption.
Poor or no connection of the charging module ground wire may cause the charging module communication interruption.
The overload of the charging module will cause communication interruption. If the ground wire is good, it can be solved by adding a communication adapter.
The wrong serial port number setting in the monitoring module will cause the charging module communication interruption.
The address of the charging module is required to be set from 0, and the address is required to be set continuously.
4. EV Charging module half-load output
Some charging modules have the function of phase loss half-load output protection. Please check the AC input voltage of the charging module.
5. The EV charging module voltage output cannot reach the set voltage
Overloading of the charging module will cause current limiting so that the output voltage of the charging module cannot reach the set value.
Battery current detection error will cause the charging module to limit the current and fail to reach the set output voltage value.
Bluesky EV Charging module detection