DC fast charging is a vital element that provides drivers with enough energy in the shortest possible charging time, especially on long trips. To achieve this, the efficiency of such charging stations is an important performance maximizing energy output per charger chassis and minimizing cooling requirements. TDK Electronics is a one-stop supplier for passive key components in DC fast chargers.
Typical block diagram of 3 Phase Charger
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B594**J-Series
TDK's J404 series of PTC inrush current limiters are the world's first in SMD packaging, reducing board space and weight by up to 70%. In addition, they can be quickly assembled at the customer's site without the need for wave soldering, thanks to pick-and-place technology. These self-regulating and intrinsically safe components limit excessive currents in DC link capacitors at the moment they are turned on or in the event of faults.
B722*
TDK's SNF series of disk varistors protect equipment like DC fast chargers from overvoltages. Suitable for use in AC and DC applications, these devices have a voltage range of 11 V to 1110 V and currents up to 10 kA, absorbing energies up to 440 J.
B88069X*
TDK's A71 and EHC6 series of gas-filled surge arresters can absorb even more energy as varistors. These components are available with rated DC spark-over voltages ranging from 800 V to 5500 V and from 800 V to 4500 V, respectively. With the use in series with varistors the leakage current can be reduced to an absolute minimum.
B82747*
TDK's B827417 is a series of current compensated 3-phase ring core chokes. They are particularly suitable for DC input and output filters as well as for DC link applications since their leakage inductance is only about 0.65% and thus the interference suppression is very symmetrical.
B3292xP
TDK's B3292*P series of MKP-X2 suppression capacitors offer a higher maximum allowable operating temperature of +125 °C compared to conventional components. Even under harsh environmental conditions, their capacitance remains stable, as proven by the thermal humidity bias test with ambient conditions of +85 °C, 85 % RH, and an operating voltage of 240 V (AC) over 500 hours.
EMI filters
TDK's broad range of EMI filters can be used at the input and output of EV charging applications, especially the B84144A0080R249. This 4-line EMI filter is designed for a rated voltage of 300/520 V (AC) and can be used for a rated current of up to 80 A. It has a safe-to-touch terminal so that it is easy and safe to install. Thanks to the compact design it has just a weight of 5.5 kg with a very low leakage current.
B3202xH*
TDK's B3202*H/J series of MKP-Y2 suppression capacitors offer a higher maximum allowable operating temperature of +125 °C compared to conventional components. Even under harsh environmental conditions, their capacitance remains stable, as proven by the thermal humidity bias test with ambient conditions of +40°C, 93% RH, and an operating voltage of 300 V (AC) over 1000 hours.
PFC Chokes
TDK's PFC chokes allow voltage and current waveforms to be in phase, maximizing the available power to power circuits and making them more efficient. Since less power is wasted in the form of heat, components can be smaller, saving size and cost. Furthermore, such chokes can “smooth out” the AC waveform reducing harmonics, and allowing the circuit to meet emissions regulations. They are available in ratings up to 100 kvar.
CUSTOMIZED SOLUTIONS ON REQUEST
B58031*
TDK's CeraLink capacitors are well-suited for snubber circuits in applications using fast-switching SiC MOSFETs. These components have a maximum capacitance of up to 1 µF at their specified operating point (positive bias behavior), and this even increases proportionately to the share of the ripple voltage. Keeping the balance between high current handling capability and capacitance, CeraLink may reduce the number of needed capacitors compared to MLCCs in consideration of total solution cost.
B3271xH*
TDK's B3271*H series of MKP film capacitors are an excellent choice for DC link applications as they combine low self-inductances as low as 11.5 nH with high ripple current capabilities. Therefore, they fit very well with SiC-based inverters operating at high switching frequencies, as often used in DC fast chargers.
B43548*
TDK's B43548 series of aluminum electrolytic capacitors are key components for highly efficient EV charging applications. Because of their outstanding ripple current capability, and their robustness and resilience against rapid charging and discharging cycles, they also meet the demanding requirements of demanding converter applications.
Ferrite core shapes E, ETD, ER, EQ, EFD, EV, ELP, RM, RM LP, PM, PQ, U
TDK's newly developed ferrite material N91 is especially well suited for high-voltage applications. It shows the highest saturation flux density of 465 mT at +100 °C. Focusing on power inductors and storage chokes, often in combination with air gaps.
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Distributed Air Gap Ferrite Portfolio
TDK's DG cores have distributed air gaps resulting in higher efficiency and significantly increased power density in power transformers, power chokes, and PFC chokes for EV charging stations. TDK introduced the E80-DG and E100-DG cores in a standard portfolio with 3 and 5 air gaps. Cores can be stacked to achieve high power classes e.g. 11 kW, 22 kW, etc.
B78418A*
TDK's EP11 SMD current sense transformers are used for overload sensing, load drop/shut down detection, and switching current detection in chargers. A special feature of the components, which measure only 13.25 x 12.6 x 14.0 mm and weigh 4.5 g, is the potted primary winding, so that the clearance and creepage distances are 3.9 mm and 6.0 mm, respectively (IEC 61558-2-16), and the SMT transformers can withstand an AC test voltage of 2.5 kV for 1 s.
B82559A*
Buck/boost choke for 48 V on-bord converter. DC-DC converters.
TDK's ERU33 high-current chokes can conduct currents up to 83 A with very compact dimensions of only 33 x 33 x 15 mm, with an upcoming expansion of the series up to 130 A. This is more than enough for demanding DC-DC converters in space-constraint applications like DC fast charging modules. By thermally connecting the flat windings to the core, the large ferrite surface area can be coupled to a heat sink for effective heat dissipation.
TDK's customized AC or DC reactors as well as MF/HF transformers with a rated power of up to 100 kW and rated voltages of up to 3 kV. Customers can choose from a variety of winding materials and insulation classes tailored to their needs. In addition to ferrite, TDK Electronics can use any other commercially available core material suitable for a frequency range between 10 kHz and 300 kHz.
B82747*
TDK's B827417 is a series of current compensated 3-phase ring core chokes. They are particularly suitable for DC input and output filters as well as for DC link applications since their leakage inductance is only about 0.65% and thus the interference suppression is very symmetrical.
B3292xP
TDK's B3292*P series of MKP-X2 suppression capacitors offer a higher maximum allowable operating temperature of +125 °C compared to conventional components. Even under harsh environmental conditions, their capacitance remains stable, as proven by the thermal humidity bias test with ambient conditions of +85 °C, 85 % RH, and an operating voltage of 240 V (AC) over 500 hours.
EMI filters
TDK's broad range of EMI filters can be used at the input and output of EV charging applications, especially the B84144A0080R249. This 4-line EMI filter is designed for a rated voltage of 300/520 V (AC) and can be used for a rated current of up to 80 A. It has a safe-to-touch terminal so that it is easy and safe to install. Thanks to the compact design it has just a weight of 5.5 kg with a very low leakage current.
B3202xH*
TDK's B3202*H/J series of MKP-Y2 suppression capacitors offer a higher maximum allowable operating temperature of +125 °C compared to conventional components. Even under harsh environmental conditions, their capacitance remains stable, as proven by the thermal humidity bias test with ambient conditions of +40°C, 93% RH, and an operating voltage of 300 V (AC) over 1000 hours.
B88269X*
TDK's HVC43 is a compact DC high-voltage contactor for up to 1000 V. The bidirectional design enables current flow in and out of the EV battery. At the end of 2023, a new option with mechanical auxiliary contacts will be available to detect stuck contacts. The contactor contains a hermetically sealed gas-filled ceramic arc chamber, offering outstanding extinguishing properties. It is specially designed to quickly shut down high direct currents of, for example, 50 kW DC chargers.