The shifting currents of the electric vehicle charging market

An electric vehicle (EV) charging system's 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, imaging, and photonics technologies from carefully selected partners.

To discover how we can help, we have outlined two routes, board-level, and system-level integration.

Our approach

Together, with our Field Sales engineers, we can support you at every stage of your design process, from concept to production, creating a unique electric vehicle charging system to meet the industries growing needs. Our approach to achieving this is simple: Consult. Design. Integrate delivered with the support of our Technology Centres.

We have access to market-leading customised magnetic components manufacturer specialists such as Myrra, Flux, and Noratel. You will receive the same technical support and competitive prices. Our in-depth experience with customised power supplies and magnetic components is a clear advantage when designing products for EV charging applications.

 

Designing the power conversion section:

  • You are designing your own power module: key components are inductors and transformers. The selection of a 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, and frequency controllers

Designing the full system​​​​​​​:

  • 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 electric vehicle 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
  • Monitoring services: sensors, cameras, and imaging sensors

Board-level integration


Magnetic cores for inductors and transformers

When designing 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.

 

Ceramic Bandpass Filters Ceramic Bandpass Filters Ceramic Bandpass Filters Ceramic Bandpass Filters


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.

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Common mode chokes

 

The expertise within our in-house Magnetic Products Technology 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%
 
  • Made of Ferrite and Nanocrystalline cores
  • Cost-efficient solution
  • Operating temperature: -40℃ to 125℃
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 a well structured team of technical support specialists in Europe, we are able to design with you 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
  • 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


Temperature sensors

Temperature sensors are used across a range of applications in electric vehicles, such as temperature monitoring of the charging cable, charging pile and battery system management (BMS). These applications call for sensors that are suited to harsh environments, accurate measurement, fast detection of a change in temperature, enhanced reliability and quality.

With Shibaura’s high-quality glass encapsulated thermistors, which provide superior performance, quality and reliability, our temperature sensors are able to withstand high voltages and temperatures up to 1000°C.

 

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Tewa TT0
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Shibaura A1

Shibaura MP3 series

 

Shibaura EP2 series

Shibaura’s MP3 thermistor sensor with
Flurocarbon sealing.

Heat, oil and solvent proof, making them ideal for motor coil temperature detection applications.

 

Shibaura’s EP2 thermistor sensors with a glass encapsulated thermistor.


Ideal for EV charging applications, with customisable cable lengths to suit your specific application. Wide operating temperature range and able to withstand high voltages.

See range   See range

 

Current sensors

 

Crocus Technology’s revolutionary TMR (Tunnel Magneto-Resistance) technology provides superior magnetic sensing performance. 

TMR is based on different physics phenomena. The magneto-resistance effect is the property of a device to change its electrical resistance value under the influence of an external magnetic field, therefore allowing enhanced electrical detection of magnetic fields. TMR current sensors can replace many Hall Effect, AMR and GMR technology based sensors with increased performance at similar price levels.

  • Excellent working dynamic range
  • Typical total output error of less than +/-0.5%
  • Capable of sensing current as low as 5mA

System-level integration


DC and AC power conversion

When designing a charging solution by integrating blocks, fast DC-charging modules, AC/DC converters, high-power transformers, EMI filters and shielding, current transformers and power supplies are some of the products we offer.

Payment services and user interfaces: 2G/3G/LTE modules, LoRa, WiFi, Bluetooth®, and RFiD technologies are also available for system design solutions.

Ceramic Bandpass Filters Ceramic Bandpass Filters


DC charger

 


AV charger

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



 
  • High efficiency >= 95%
  • Power factor >= 0.99
  • Can support busses
 

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 weatherproof construction.

 

  • Power ratings from 3.6kW up to 22kW
  • Charging speeds up to 8x faster than standard models
     


Customised converters and chargers

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

Electric vehicle 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). Electric vehicle 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 ( Acal BFi kOr 118 and 120).

  • 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


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 electric vehicle 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. Electric vehicle 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 (FoF) 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

 

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Infrared sensors
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LiDAR


Infrared sensors

 


LiDAR

Teledyne 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 both night and day.

However, in an electric vehicle application, they can be used to optimise system management, detecting heat spikes and they can be used to improve the accuracy of vehicle detection in automated electric vehicle charging facilities.

Teledyne FLIR offers a range of SWIR, MWIR, and LWIR infrared sensors to provide accurate data managing your electric vehicle 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 electric vehicle
charging systems and vehicles with precise, real-time and 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 additional reliability, so they are ideal to be designed into electric vehicle charging systems.


Intelligent wireless connectivity

Electric vehicle 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

 

Fibocom FM160 series

Offering low-cost and extremely low-power technology, covering worldwide 2G/3G/4G networks.
 
  • 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 highly integrated 5G wireless communication modules which come either in a M.2 form factor interface or a solder-down LGA variant.

  • M.2 formfactor (dimensions: 30 x 52 x 2.3mm)
  • Compatible with Fibocom’s FM150 family
  • LGA version FG160-EAU available
  • LGA dimensions: 41 x 44 x 2.75mm
  • Multi-constellation GNSS receiver
  • Maximum downlink rates: 3.5Gbps
  • Uplink rates up to 900Mbps
  • Operating temp: -30°C - +75°C
  • Power supply: 3.1 – 4.4V
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 lowpower, long-range devices, for high sensitivity communication to easily communicate at regional, national, and even global levels.

This 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.

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


     
  Offering a unique combination of two leading IoT radio technologies in one class-leading miniaturised package. With integrated BLE and LoRa, these modules offer the long-range capability of LoRa for data transmission across distances, combined with the high-throughput flexible service of BLE for a short-range connection.
 
  • 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
See range   See range

How can we help?

 

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IEC62196-2 combo charging plug
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HVSL series rated to 1000V with current 350A (2W) 250A (2W) 46A (6W)


IEC62196-2 combo charging plug

 


High voltage EV connector systems

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 and are equipped with a temperature sensor and a coloured LED to monitor charging status.

  • 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)
 

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, touch-proof, 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)
See range    

How can we help?

Technology Centres

When resource or capacity is limited, you can depend upon our knowledge and dedicated Technology Centres to support you from concept through to production.

We provide access to a large range of specialist services and capabilities across our specialist technologies, enabling you to build tailored solutions and bring your concept to reality. Discover how we can support you through our dedicated centres.