Technical requirements of electric vehicle batteries and chargers are not always the same, and this lack of knowledge can lead to confusion during EV charging. For most of the electromobility sector, the higher the power, the more problems arise, due not only to the high technology required by the chargers, but also to the way in which they must adapt to the batteries.
The true challenge arises with batteries that require lower voltage. Since the result of the charging power is determined by both the voltage and the amperage involved, the higher the voltage and amperage, the higher the power a charger can deliver and, consequently, the faster the charging speed can be. However, not all batteries operate at the same voltage: while some vehicles can operate at 800 volts, allowing very fast charging easily, most cars on the market operate at around 400 volts. This means that in order to deliver the same amount of kilowatts to the batteries, the amperage must be increased.
In this sense, many of the chargers on the market -limited to a current of 250 amps- can achieve up to 150 kW of power in the case of vehicle batteries operating at high voltages. But the vast majority of chargers encounter problems when working with voltages of 400 volts, resulting in a lower charging power. How could anyone overcome this pitfall? With technology, patience and knowledge.
More power without liquid cooling: the benefits of “Boost mode”
During the designing process of its ultra-fast charger Raption 150 Compact, Circontrol faced this problem and developed the “Boost mode” to increase the amperage at which the charger works without exceeding safe temperature limits or using liquid cooling, which sometimes can be very expensive. To achieve this, the manufacturer designed its own control algorithm linked to a software solution that regulates the charge according to the temperature of the connector, ensuring a perfect balance between these parameters, always within safety margins.
Thanks to this solution, the Raption 150 Compact can increase or limit the amperage according to the voltage required by each battery, thus providing 150 kW as long as the vehicle can support it. This makes the charging process as reliable as possible, allowing the time spent in the process to be kept to a minimum and thus facilitating the charge for more electric vehicles in the same amount of time. But how does the control algorithm that enables the “Boost mode” works?
Maximum safety keeping a high charging speed
Circontrol’s control algorithm works by limiting electric power whenever is necessary. First, it gathers information from a thermal meter located in the connector itself and, in the event of temperature high increase, it limits the charge to guarantee optimum operation at any time. Thus, whenever the connector exceeds 85°C during the charging process, the control algorithm triggers the command to reduce the amperage until it is within safe temperature limits for the vehicle.
This automatic regulation can be performed thanks to the Raption 150 Compact’s power balancing system that regulates the energy delivered through its twin power blocks. When the higher amperage makes temperature rise and the control algorithm is activated, the 25 kW modules of the blocks automatically reduce the energy they are working with to adapt to the needs of the vehicle, and continue working within safe limits. Thus, by this process, Circontrol’s Raption 150 Compact can adapt to all types of batteries present in current and future electric vehicles.
With the advantage of the “Boost mode”, Circontrol ensures a stable and safe 150 kW charge as long as the electric vehicle supports it, regardless of the voltage of its battery, to suit all users’ needs. An honest commitment to electromobility which, according to the company, is the only way to build a long-lasting electric future for everyone.