The shifting currents of the EV charging market | Acal BFi SE

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Manufacturer's part number Product description Qty
Manufacturer's part number Product description Qty

Powering the future of EV charging

EV Charging system core design is the power conversion module. Some customer have the expertise and capability to design and produce the power module, others buy directly from an experienced partner.

In either approach, there will be a system design which includes all the necessary features for effective charging management.

Acal BFi offer a portfolio of specialist magnetic, power, wireless, sensors and imaging technologies from companies of the parent group (discoverIE group PLC) and high-quality suppliers. Together, with our design engineers, we can help you every step of your design process from idea to production, creating a unique EV charging design to meet the industries growing needs.

To help you discover how we can help we have outlined two routes Board or System Integration level.

Board level

  • You are designing your own power module: key components are inductors and transformers, the selection of magnetic core is the extremely important to achieve the best efficiency of your converter. We can also offer SMD power inductors, EMI filters, current sensor, temperature sensors, thermally conductive products to extract heat from hot spots and frequency controllers.

System integration

  • You are designing your charging solution by integrating blocks: fast DC-charging modules, AC/AC converters, high-power transformers, EMI filters and shielding, current transformers and power supplies are some of the solutions we offer.
  • Essential EV charging plug and connector systems
  • Payment services and user interfaces: 2G/3G/LTE modules, LoRa, WiFi, Bluetooth and RFid technologies. Our embedded solutions can support these technologies.
  • You want to add monitoring services: select our sensors, cameras or imaging sensors.
  Magnetic cores | CMC | Designing compact products | Thermal conductive products | Temperature sensors | Current sensors

 

Magnetic cores for inductors and transformers

When developing inductive components like transformers and inductors, choosing the right material is the first challenge. There are over a dozen material classes, with a huge variety of sub-classes, brands, grades and types. A developer has to match their applications requirements with the parameters of each material and give consideration to the cost implications.

Our portfolio covers a wide range of specialist soft magnetic materials including EDGE, XFlux, Kool Mu Max from Magnetics Inc., Iron Powder from Micrometals as focus materials for inductors; Amorphous, Nanocrystalline from our Acal BFi kOr product line and Ferrites from Ferroxcube for transformers. We can help you select, source, customise, stock and integrate soft magnetic cores.





Suitable materials

Edge:
  • High saturation flux density 1,5T
  • 40% lower losses respect to high flux
  • 30% higher DC bias
  • FeNi composition
Nanocrystalline kOr 120 & kOr 122:
  • High saturation, flat hysteresis loop (F-loop)
  • High linearity µ(DC) and µ(f)
  • Low losses
  • High operational temperature, up to 200°C
  • Adjustable permeability up to 200K
  • Toroidal & custom shapes available
Iron Powder for power conversion:
  • Most cost effective magnetic materials, high saturation
  • Moderate losses
  • Permeabilities up to 100
  • Wide range of geometries and sizes

Kool Mu Max:

  • Supercharged sendust with 50% better DC Bias
  • Very low losses
  • 14 to 60 permeabilities
  • AlSiFe powder

 


     

    Common Mode Chokes for EMI filters: cores and components

    When designing modern and often complex integrated systems, engineers must take into account the possibility of electro-magnetic interference (EMI), which affects the performance of the system and can lead to a failure to meet regulatory standards. To contain conducted emissions the usual solution is to add a filter at the input stage of your system and common mode chokes (CMC) are the basic component of the filter. This allows the target signal to pass unaffected, whilst filtering out undesired signals. It is important that reliable, functional and affordable materials are used to create these components to avoid the saturation of the magnetic core, allow the correct efficiency in the desired frequency range and set the appropriate differential inductance.

    The expertise of our in- house R&D centre enable us to select the right material and design the best core to build your common mode choke We offer nanocrystalline (see inductors and transformers section) and ferrite cores

    We can also offer a list of ready-made common mode chokes from our suppliers Magnetec and Laird.




    Suitable materials

    Ferrites
    • Lowest cost magnetic materials, low saturation
    • Low losses
    • Permeabilities up to 15000
    • Very wide range of geometries and sizes
    Nanocrystalline kOr 120 & kOr 122
    • High saturation, flat hysteresis loop (F-loop)
    • High linearity µ(DC) and µ(f)
    • Low losses
    • High operational temperature, up to 200°C
    • Adjustable permeability up to 200K
    • Toroidal & custom shapes available

    Common mode chokes

    Magnetec
    • Made of Nanoperm, proprietary nanocrystalline cores
    • 60% size reduction compared with ferrites
    • Standard tolerance of the nominal inductance: +50%/-30%
    • Designed to meet EN60938-1 for 230V and 500/600V mains voltage

    Laird

    • Made of Ferrite and Nanocrystalline cores
    • Cost efficient solution
    • Operating temperature -40℃ to 125℃
    • Available in PTH and SMD technologies

     


       

      Designing compact products / Bespoke specifications

      Designing compact product? Then you may want to consider planar magnetic components

      If you are designing a lightweight, compact power converter, the Planar transformers and inductors are highly efficient and low profile which is ideal for demanding applications with restrictive space and efficiency requirements with easy component integration.



      Champs Technologies are committed to providing high-quality, engineering-focused innovation with quality assured by ISO9001-2015, UL File #251699 and Conflict Minerals Compliant certifications.

      In addition, Ferrite planar cores have:

      • Wide input range and power
      • Capable of an embedded solution
      • Reference designs


      Bespoke specifications? We can provide and design Custom magnetic components

      Being part of the DiscoverIE Group, Acal BFi has access to market leading customised magnetic components manufacturer specialist such as Myrra, Flux, Noratel, you will receive the same technical support and competitive prices. Our indepth experience with customised Power and Magnetics is a clear advantage when designing products for EV-charging applications.

      You can select from a wide range of different solutions, optimising your inductors and transformers rated from 0,1W to 300kW. We focus on helping customers to create a solution with high efficiency, low losses, effective heat management, easy mounting and competitive cost.



      A typical project, starts by us exploring the customers application from the primary electrical and mechanical specifications. When the specifications has been agreed, we utilise our wide knowledge of core types and materials, wires and insulation, thermal management, materials and production cost to define the optimal solution. On design and cost approval, we will produce prototypes for customer testing and approval.

      • R &D expertise to design or review your projects
      • Extensive knowledge of plastics, metals, moulding for magnetic components
      • Quality management – ISO, AS, OHSAS, MIL, ESCC, UL
      • Fast prototyping and manufacturing capabilities
      • On time shipment and long term logistics service


         

        Thermal conductive products

        High current power conversion produces heat which must be dissipated safely to avoid overheating causing EMI issues or even premature failure of electronics inside the application. Acal BFi can offer market leading thermal interface materials from MTC,that combine high thermal conductivity and low viscosity whilst maintaining insulating properties.



        This customisable range includes:
        • Thermal conductive paste
        • Gap filler
        • Thermal conductive tapes
        • Thermal conductive insulators
        • Phase change material
        • Graphite foil
        Common characteristics to all these materials are:
        • UL-94-V0 certified
        • Thermal conductivities in the range of 1.0 W/m*K up to 20.0 W/m*K.
        • Die cut and kiss cut parts upon request
        • Silicon free gap fillers
        • R&D capabilities for temperature modelling
        • Quality management – ISO 9001 & 14001 RoHS & REACH
        • Really fast prototyping and manufacturing

         


           

          Temperature sensors

          Temperature sensors are used across a range of applications for electric vehicle charging, such as temperature detection of the electric motor, temperature protection of the on-board charger, charging cable and the charging pile as well as battery system management (BMS), making sure to activate an automatic shut-off in case of hazardous electrical faults.

          These applications call for sensors that are suited to harsh environments – with a higher tolerance, stability and durability, offering customisation of the sensor in accordance with the varying requirements of shocks and conditions for different vehicles.

          With Tewa and Shibaura’s high-quality and sensitive technology, we offer a wide range of temperature sensors with plastic, metal or epoxy encapsulation able to withstand temperatures up to 1000°C, with IP68 rated over-moulded probes offering a level of customisation of housings, coatings and cables that can be designed to meet the most demanding environments.

          Tewa TT0 Series

          Temperature sensors



          TEWA’s TTO series sensors are IP68 waterproof temperature probes encapsulated with thermoplastic elastomer materials in over moulding technology, specifically designed and dedicated for harsh environmental conditions. The probe is available in a wide range of standardised sizes and tolerances with a single, double or triple reinforced insulation.

          • Excellent insulation against moisture
          • Degree of waterproof protection IP68
          • Flexible size of tolerances (smallest tip diameter 4.5 mm)
          • Excellent resistance to UV (black insulation)
          • ROHS compliant and Halogen Free
          • Wide range of R/T characteristics
          • NTC and PTC thermistors, PtRTD versions are available

           
           

          Shibaura A1 Series

          Thermistor sensors



          Shibaura’s A1 Thermistor sensors are ideal for EV charging applications which are high and low temperature, oil and solvent proof because of their fluoro resin sealing.

          Shibaura are fully customisable to meet the demands of complex designs.

          • Applications: Electric motors for EV, HEV and their inverter temperature measurement etc.
          • Operating temperature range: -40 to 200°C(250°C for a short time)
          • Thermal time constant: Approx. 4 sec. (in liquid)

          Current sensors

          Among all the techniques used to measure current at board level Aceinna is offering an innovative and unique solution that enable engineers to keep a compact design and accurate measurement. Their AMR technology provides excellent accuracy over temperature and with lower noise and offset provide higher accuracy over the current dynamic range vs Hall Effect competitors. AMR technology is also offering a higher bandwidth sensor to enable fast step in protection circuits

          Aceinna AMR technology current sensors

          ACEINNA is a leading supplier of MEMs-based sensors products and is focused on designing and marketing benchmark performance sensors in high-growth markets.

          • Excellent accuracy and over temperature: 20A and 50A Total max error 0,7%@25°C
          • Very High Frequency Response: 1,5Mhz bandwith
          • Integrated fast over-current-detection
          • 4.8kV galvanic isolation

           


             


              DC and AC power conversion | Customised converters and chargers | Current sensitivity components | Transformers | IR sensors | LiDAR | Intelligent wireless connectivity | Cellular Modules| EMI Shielding | Plug connector

            DC and AC power conversion products for EV and battery charging

            We offer OAKSUM’s high efficiency DC and AC power conversion products for EV and battery charging. The range includes DC converters up to 30KW, suitable for multiple connections to total powers more than 250KW, Bidirectional power converters (suitable for V2G) and a complete range of smart and affordable AC EV charging modules.

            DC charger



            These modular AC/DC power dense converters are specifically designed for fast DC charging including: E-Bus & Service vehicle operators, EV manufacturing lines, EV workshops, EV fleet operators.


            • High efficiency >= 95%
            • Power factor >= 0.99
            • Can bus supported
            • Parallel operations to create high total power systems
            • Input/output low & over voltage protection, short circuit protection, over temperature protection

             
             

            AC charger



            The OAKSUM smart AC EV chargers are designed for maximum charging performance combined with high energy efficiency. The IP65 casing gives a robust and compact weather-proof construction, suitable for both indoor and outdoor installations.

            These smart EV chargers also include the capability for various authorisation methods such as RFID, wireless communication and key switches.

            • Power ratings from 3.6KW up to 22KW
            • Charging speeds up to 8x faster than standard models
            • Safety standards compliance
            • System payment integration
            • Simple installation
            • Low maintenance
            • 3 year warranty

            Customised converters and chargers for EV

            Acal BFi work in partnership with OAKSUM to customise and manufacture converters and chargers for EV. Together we have the in-depth experience and a wide variety of services to help with the process of finding the right power supply for your specific requirements.

            OAKSUM also offers a range of options to brand and customise the products look and feel, including a choice of case colour, customer’s logo and branding.

             

             

             

             



             

            Current sensitivity components

            EV charging systems require the capability to measure current in order to detect uncontrolled situations which may cause permanent system failures.

            Our Custom service for magnetic components offer cores for different type of RCDs (residual current devices). EV charging requires all-current sensitivity, detecting pure DC currents and any currents with higher frequencies above 50 Hz. We are able to tune properties (hysteresis loop shape, permeability, temperature behaviour) of nanocrystalline cores (kOr 118, kOr 120) according to specific requirements and support developers with our expertise and samples.

            • Optimum combination of high linearity and highest permeability
            • Negative temperature coefficient µ(T) (as standard)
            • Plastic case or epoxy coated for example as RCCB core: Bdyn/Bsin > 0,85 at µmax = 150.000 and >0,80 at µmax = 200.000


            Current transformers are integral to EV charging, providing galvanic isolation from the voltage on the primary winding while simultaneously furnishing a power signal that has been converted to a standard level. We offer a specialist range of standard product of current transformers, designed and manufactured in accordance with specified standards (IEC, VDE, BS). Standard range of current transformers are available for primary currents from 10 Amps to 10000 Amps and accuracy classes from 0.1% and higher for specified burdens and overcurrent values.

            Through Acal BFi you can access to Noratel’s standard and custom products.

            • Wide range of current capabilities
            • Fully certified according standards
            • For Measuring or protection applications
            • Various mechanical solution for primary section


             

            Transformers

            When power management rating increase, you may need 50/60Hz transformers to connect your charger system to the grid. We offer a specialist range of transformers designed for smoothing in rectifiers, reducing short-circuit currents, AC filtering and high frequency switching.

            These transformers are manufactured according to a customer’s exact requirements. Noratel is able to design and produce anything from small single-phase toroidal to large tri-phase EI transformers with heavy current coils for larger EV charging installations, everything developed in close co-operation with the customer.

            • Power range from 0,1KVA – 300 KVA
            • Isolating transformers
            • Transient suppression transformers
            • 3-phase transformers
            • Toroidal transformers

             

            IR sensors

            FLIRs IR sensors have a proven history of being used for human detection and security applications because of their low power consumption and because they are effective night and day in a variety of environmental conditions. However, in an EV application they can also be used to optimise system management, detecting heat spikes and they can be used to improve the accuracy of vehicle detection in automated EV charging facilities.

            FLIR offer a range of SWIR, MWIR and LWIR IR sensors to provide accurate data managing your EV charging system.

            Need help with a custom IR sensor

            Our IR specialists offer personalised and responsive support to customers at every stage of a project, providing samples and technical support. We also offer an exclusive range of specialist lenses which can be integrated and configured by our custom services centre.


             

            LiDAR

            Our specialist products provide the EV charging systems and vehicles with precise, real-time, distance measurements, the multi-segment optical sensing technology provides narrow to wide fields of view with lateral discrimination, enabling multiple object detection and distance measurements.

            We work with our market leading partners Leddartech to offer a LiDAR range which includes products with no moving parts for reliability, so they are ideal to be designed into EV changing systems


             

            Intelligent wireless connectivity

            EV charging infrastructure requires the highest level of performance to overcome connectivity and logistical challenges of deploying across large areas. Using the right technology is key for critical applications such as remote operation, predictive maintenance, payment and energy control functions by overcoming the difficult coverage, capacity and cost barriers for multiple locations at any one time.

            With modules designed specifically for remote device deployment, you can design using best-in-class ready-to-connect, future-proofed modules that provide SIM connectivity to devices anywhere in the world.

            Cellular Modules

            Offering low cost and extremely low-power technology, ideal for low-bandwidth IoT applications, covering worldwide 2G/3G/4G networks. Fully compliant with release-14 and 5G, and ready to support future features.

            Sierra Wireless AirPrime RC Series

            • Optimized 4G LTE Cat-1 connectivity with 3G fallback
            • Compact CF3 design to migrate between technologies
            • Ready-to-connect
            • Embedded Sim for global coverage
            • TCP/IP Stack – embedded stack to easily communicate over the internet
            • VoLTE – Voice over LTE
            • Cloud connected – for secure collection of data and remote management of IoT deployments with integrated AirVantage services

            Sierra Wireless AirPrime MC7455 M2M module

            Offering unprecedented LTE speeds, bandwidth, and network performance on the PCI Express Mini Card form factor commonly used in networking equipment.

            • Optimised 4G LTE Cat-6 IoT connectivity with 3G fallback for the Americas and EMEA
            • Delivers up to 300 Mbps download speed
            • Supports most EMEA and NAM bands on a single SKU
            • Automatic fallback to 3G networks
            • Dual SIM single standby (DSSS) switches between networks quickly to stay connected
            • Securely collects data and remotely manage your IoT deployments with integrated AirVantage® cloud services
            • Location Services - GNSS receiver enables tracking and location-based services
            • TCP/IP Stack - Embedded stack to easily communicate over the internet
            • Programmability - Basic and Extended AT Commands simplify development
            • Industrial-Grade - Tested for harsh environments and extreme temperatures

             

            LoraWAN

            Designed to enable very low-power, long range devices, for high sensitivity communication to easily communicate at regional, national and even global levels. The WLRS-590 also provides significant advantages in both blocking and selectivity over conventional modulation techniques, solving the traditional design compromise between range, interference immunity and energy consumption. WLRS-590 module provides a commands set interface that can use LoRa and LoRaWAN communication through UART interface.

            SparkLAN WLRA-590 LoRa IoT module

            • Based on Semtech SX1276
            • STM32L073xZ ARM Coretex-M0+
            • Support for 868 MHz and 900 MHz
            • SiP module
            • Dimensions 13 x 11 mm

            Insight SiP iSP4520 series - Built-in Antennas Combo LoRa and BLE modules

            The ISP4520 offers a unique combination of two leading IoT radio technologies in one class leading miniaturized package. With integrated BLE and LoRa, this module offers long-range capability of LoRa for data transmission across distance, combined with the high-throughput flexible service of BLE for a short range connection for configuration, commissioning and update via smartphone or tablet.

            • Optimised 4G LTE Cat-6 IoT connectivity with 3G fallback for the Americas and EMEA
            • Delivers up to 300 Mbps download speed
            • Supports most EMEA and NAM bands on a single SKU
            • Automatic fallback to 3G networks
            • Dual SIM single standby (DSSS) switches between networks quickly to stay connected
            • Securely collects data and remotely manage your IoT deployments with integrated AirVantage® cloud services
            • Location Services - GNSS receiver enables tracking and location-based services
            • TCP/IP Stack - Embedded stack to easily communicate over the internet
            • Programmability - Basic and Extended AT Commands simplify development
            • Industrial-Grade - Tested for harsh environments and extreme temperatures

             

            EMI shielding

            For safety and reliability, it is critical that charging stations fully meet the industries requirements.

            EV charging stations equipped with advanced capabilities such as power electronics and cloud-based communications fall under the class of devices that require EMC testing and certification.

            For safety and reliability, it is critical that charging stations fully meet the industries requirements. To help protect your device we offer broad range of components and materials for the shielding of EMI, such as:

            • Fabric-over-foam gaskets, electrically conductive foams, elastomers, tapes and contact springs.
            • Shielded windows, metal honeycomb vent panels and fan vents
            • Metal contact springs and pads
            • FOF made of aluminium foils or copper-nickel fabric
            • Different shapes, thickness, hardness, metals available
            • Attenuation 60 - 90 db @ 100MHz – 18 GHz
            • Mechanical simulation capabilities for contact spring
            • Copper-Berilium made with gold-plating finishing

             

            EV charging plug and connector systems*

            * Please note these product are only available for sale in the UK.



            IEC62196-2 Combo Charging Plug


            The Excel|mate CC – IEC Combo developed by Amphenol meets the IEC 62196-2 Standard for charging systems enabling the vehicle to be charged with AC and DC power.

            The combo plug includes 2 DC power contacts enabling rapid charging in public areas. To be able to monitor the charging status as well as the temperature, the vehicle inlet and the combo plug are equipped with a temperature sensor and a coloured LED.

            The Excel|mate CC IEC Combo is available for 60, 125 and 200 A and in custom cable lengths.

            • Compliant to IEC 62196-3
            • Rated Current 200 A
            • Rated Voltage 1000 V
            • Mating Cycles > 10.000
            • Temperature sensor included
            • Ambient temperature -30° to 50°C
            • Protection class IP 44 (mated)

            High Voltage EV Connector Systems up to 1000V / 350A

            Supporting EV and HEV platforms with ratings up to 1000V @ 350A. Connector ranges include types for drive motors, battery systems, power distribution and control units. Both the Amphenol HVSL and MSD product families feature EMI shielding, touchproof, interlock and second lever locking.


            HVSL series rated to 1000V with current 350A (2w) 250A (2w) 46A (6w)




            MSD series rated to 1000V with current 300A (MSD XL)


             
             


            Additional featured key technologies / applications

            Please find below a selection of articles featuring some of our key markets and technologies.


            Custom services for magnetic components

            learn more

            Find out more about the high-quality amorphous and nanocrystalline cores product range you can access from Acal BFi kOr

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            A user guide to soft magnetic materials

            learn more

            A user guide to soft magnetic materials

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            Turning great ideas into customer success – how Acal BFi are solving IoT design challenges

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            Designing a cleaner future with smart sensor solutions

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            Reach new heights with our specialist UAV solutions

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            Find out more about our power components and solutions for industrial applications and equipment

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