Porsche Engineering has developed a fast charging system with modular building blocks so that it fits charge parks of various sizes and takes into account the grid and visitor frequency. It builds on the 800-Volt technology also used in their high power charging solution.
The solution by Porsche Engineering has been designed for charge parks with different demands and constraints. It consists of the usual components but Porsche has managed to repack them in a way that enables greater flexibility in installing the fast-charging station for electric cars.
First, there are the FlexBoxes (120 x 120 x 130 cm), weather-proof housings designed to hold all other components and that can be installed out of sight from customers. These boxes can cover the transformer for example, in charge parks where a connection to the medium-voltage grid exists. A transformer converts this medium voltage (AC) into low voltage (local grid level). The Porsche design of the transformer also allows to fit the galvanic isolation inside rather than adding it to each individual charging pole, where it takes up space and drives up costs.
Getting closer to the actual fast-charging station, there is what Porsche calls the PowerBox. Here, the low-voltage alternating current from the transformer station is converted into direct current (DC) needed for fast-charging.
This part can be equipped with two sets of power electronics and supply two charging points. The system utilises silicon carbide (SiC) modules, resulting in lower conduction, switching losses and space requirements.
For charging parks with a less powerful grid connection, the ChargeBox contains an additional buffer storage battery in addition to a power unit. It is available as an entry-level model with a 70 kWh battery and a 160 kW charging station. For more highly frequented locations, for electric vehicles with higher charging capacities or as a subsequent retrofit, there is also a fully equipped version with 140 kWh and two 160 kW charging stations, combinable for 320 kW.
Moreover, all components are designed to accommodate a distance of up to 200 meters between the transformer station and PowerBox and up to 100 meters between the PowerBox and the charging station.
Last but no less important especially for high power charging is the CoolingBox. It provides liquid cooling for the charging poles and power electronics. Every CoolingBox can accommodate two cooling units, each of which can cool multiple charging points under all operating conditions, says Porsche. The CoolingBox may be installed at some distance from the charging stations as well.
For operators with limited space at the charge park, Porsche Engineering as designed the ComboBox, a power unit with a cooling unit combined and sufficient for one fast-charging point for electric cars each.