The shifting currents of the electric vehicle charging market

Electric vehicle (EV) charging system core design is the power conversion module. Some customers 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 that includes all the necessary features for effective charging management.

We offer a portfolio of specialist magnetic, power, wireless, sensors, and imaging technologies from carefully selected partners. Together, with our design engineers, we can support you at every stage 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-level or system-level integration.

Board-level integration:

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

System-level 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

Board-level integration


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 application's requirements with the parameters of each material and give consideration to the cost implications.
 

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Magnetic cores for inductors and transformers


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.

 

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Nanocrystalline kOr (120 & 122)

 


Edge

 


Iron Powder for power conversion

 


Kool Mu Max

  • 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 and custom shapes are available
 
  • High saturation flux density 1,5T
  • 40% lower losses with respect to high flux
  • 30% higher DC bias
  • FeNi composition




     
 
  • Most cost-effective magnetic materials, high saturation
  • Moderate losses
  • Permeabilities up to 100
  • Wide range of geometries and sizes



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




     
See range   See range   See range   See range

 


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 electromagnetic 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.
 

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Common mode chokes


The expertise of our in-house R&D centre enables 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.

 

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Nanocrystalline kOr (120 & 122)

 


Ferrites

 

Common mode chokes from Magnetec

 

Common mode chokes from Laird

  • 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 and custom shapes are available
 
  • Lowest cost magnetic materials, low saturation
  • Low losses
  • Permeabilities up to 15000
  • Very wide range of geometries and sizes
 
  • 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
 
  • Made of Ferrite and Nanocrystalline cores
  • Cost-efficient solution
  • Operating temperature: -40℃ to 125℃
  • Available in PTH and SMD technologies
See range   See range   See range   See range

 

 

 

 

Designing custom magnetics

When designing a power conversion module for a charging application, magnetic components are vital and need to be designed using the competencies of soft magnetic cores, wires, insulation, plastics, and heat dissipation.

With the largest team of technical support specialists in Europe, we are at the forefront of a design-led approach to delivering challenging and custom solutions for magnetic cores or components within power conversion applications.

Our Magnetics Products Technology Centre can develop a solution to achieve your goals, whether your need is simple or complex.

  • Consultancy on soft magnetic cores. We not only select the best technology for you, but we can also design the best-suited core for your application
  • Starting from your basic specifications, we design the inductive component and produce rapid prototypes to test the concept
  • Manufacturing of the components, designed with you
  • Setup a dedicated logistic strategy to secure your supply chain

Typical products we can develop are common mode chokes, PFC chokes, transformers, EMI filters, and 50Hz safety and monitoring components (current transformers and RCDs).


Thermally conductive products

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

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Thermally conductive products

 

This customisable range includes:   Common characteristics of all these materials are:
  • Thermal conductive paste
  • Gap filler
  • Thermal conductive tapes
  • Thermal conductive insulators
  • Phase change material
  • Graphite foil
 
  • 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, and REACH
  • Fast prototyping and manufacturing

 


Temperature sensors

Temperature sensors are used across a range of applications for EV 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.

 

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Tewa TT0
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Shibaura A1

Tewa TT0 series

 

Shibaura A1 series

TEWA’s TT0 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 4.5mm)
  • 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’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. The A1 series is 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)
See range   See range

 

 




 

Current sensors

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

  • Excellent accuracy and over-temperature: 20A and 50A Total max error 0,7%@25°C
  • Very high-frequency response: 1,5MHz bandwidth
  • Integrated fast over-current-detection
  • 4.8kV galvanic isolation

System-level integration


DC and AC power conversion products for EV and battery charging

We offer a range of OAKSUM high-efficiency DC and AC power conversion products for EV and battery charging. This portfolio 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.

 

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DC charger

 


AV charger

These modular AC/DC power-dense converters are specifically designed for fast DC charging such as E-Bus and service vehicle operators, EV manufacturing lines, EV workshops, and EV fleet operators.
 
  • High efficiency >= 95%
  • Power factor >= 0.99
  • Can bus supported
  • Parallel operations to create high total power systems
  • Input/output low and over-voltage protection, short circuit protection, over-temperature protection


     
  OAKSUM's 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
  • Three-year warranty
See range   See range

 


Customised converters and chargers for electric vehicles

We work in partnership with OAKSUM to customise and manufacture converters and chargers for electric vehicles. Together, we have 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 product 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 Magnetic Products Technology Centre offers cores for different types of RCDs (residual current devices). EV charging requires all-current sensitivity, detecting pure DC currents and any currents with higher frequencies above 50Hz. We are able to tune properties (hysteresis loop shape, permeability, and 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
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Current sensitivity components



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 current transformers, designed and manufactured in accordance with specified standards (IEC, VDE, BS). The 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 us, you can access Noratel’s standard and custom products.

  • Wide range of current capabilities
  • Fully certified according to standards
  • For measuring or protection applications
  • Various mechanical solutions for the primary section


Transformers

When power management ratings 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.

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Charging transformers


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
  • Three-phase transformers
  • Toroidal transformers

 

EMI shielding

For safety and reliability, it is critical that charging stations meet the industry's full 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.

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EMI shielding


To help protect your device we offer a 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 are available
  • Attenuation 60 – 90 dB @ 100MHz – 18 GHz
  • Mechanical simulation capabilities for contact spring
  • Copper-Beryllium made with gold-plating finishing

 

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Infrared sensors
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LiDAR


Infrared sensors

 


LiDAR

FLIR's infrared sensors have a proven history of being used for human detection and security applications due to their low power consumption and their effectiveness at night and day and 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 offers a range of SWIR, MWIR, and LWIR infrared sensors to provide accurate data managing your EV charging system.

Need help with a custom IR sensor?

Our infrared specialists offer personalised and responsive support at every stage of a project, providing samples and technical support. We also offer an exclusive range of specialist lenses that can be integrated and configured by our Infrared Imaging Technology Centre.

 

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 LeddarTech to offer a LiDAR range that 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 the 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

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RC series
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MC7455 M2M series


Sierra Wireless AirPrime RC series

 


Sierra Wireless AirPrime MC7455 M2M 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.
 
  • Optimised 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




     
  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
See range   See range

 



LoRaWAN

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WLRA-590 LoRa IoT module
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iSP4520 series


SparkLAN WLRA-590 LoRa IoT module

 


Insight SiP iSP4520 series – built-in combo LoRa and BLE modules

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. The WLRS-590 module provides a commands set interface that can use LoRa and LoRaWAN communication through UART interface.
 
  • Based on Semtech SX1276
  • STM32L073xZ ARM Coretex-M0+
  • Support for 868MHz and 900MHz
  • SiP module
  • Dimensions: 13 x 11mm


     
  The ISP4520 offers a unique combination of two leading IoT radio technologies in one class-leading miniaturized package. With integrated BLE and LoRa, these modules offer the 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 America 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
See range   See range

 

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