Design considerations of a 50 kW compact fast charger stations using nanocrystalline magnetic materials and SiC modules

Paper in proceeding, 2016

A fast charger station can charge a vehicle battery in 5-10 minutes but it is very expensive and massive. Recent advancements in the device developments and design tools enables one to have a higher power density (power divided by volume) chargers that is equivalent to a smaller size and weight. Semiconductors based on Silicon Carbide (SiC), magnetic materials based on Nanocrystalline and modern design tools like FEM simulators are examples of these advancements. Some design aspects of a 50 kW fast charger station is presented in this paper. The charger main specifications, the main topology candidates to achieve a compact design, some simulation results and constructed transformer are presented and discussed. For the DC/DC stage two designs are presented based on the full-bridge (FB) and dual active bridge (DAB) topologies. Some comparison results are described in this paper.