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Comprehensive solutions for fast EV Charging design

From power and control to sensor and security


E-mobility is the future. It will revolutionize private and public transportation, reduce air pollution and make our world a better place. Creating efficient charging infrastructures is key to enabling this worldwide megatrend. However, if people are to embrace this technology, charging infrastructures must allow drivers to travel conveniently, and charge their vehicles quickly and safely.

Different DC charging systems are available for different use cases:

Home use

DC wallbox ≤ 22kW
Single entity
Charging time for 200km = 120min

Public use in cities

Charger ≤ 150kW
Multiple subunits, each subunit ≤ 30kW; galvanic isolation in each subunit
Charging time for 200km between 15 and 50min

Highway use

Charging park with multiple chargers, each ≤ 350kW
Each charger has multiple subunits ≤ 60kW, typically with a non-isolated topology
Charging time for 200km = 7min

Different charging stations have different requirements: In general, however, they must be small and light, the inverter needs to provide high power, and the charging process needs to be fast. The power electronics used in these systems have to ensure high power density, low cooling effort and reduced system size. This means that a number of challenges have to be overcome:

High power density is an advantage for fast charging but it is also a challenge for thermal management. Public charging stations, for example, need higher power densities to enable high-power charging. In these stations, liquid cooling has become the standard for overcoming thermal issues.

Chargers must also be small and convenient. Higher switching frequencies are used to save space and reduce the size of magnetic components.

Infineon's unique expertise in e-mobility and power supplies make it the natural partner for increasing the efficiency and performance of electric vehicle (EV) charging applications, enabling customers to optimize costs and develop innovative solutions.

Infineon offers a broad portfolio of benchmark products ranging from power and control applications to sensors and security features. The following diagram shows the company's key portfolio for DC EV charging designs:

Power conversion

Infineon offers solutions with either discrete IGBTs or modules for different DC charging systems and power levels. Discrete devices are typically used for charger solutions in the 30kW to 150kW power range.

Infineon particularly recommends the 600V CoolMOS™ P7 family, the 650V IGBT TRENCHSTOP™ 5 family and the 1200V CoolSiC™ Schottky diode for the Vienna rectifier in the PFC stage. For the converter in the DC/DC stage, Infineon recommends the 600V CoolMOS™ CSFD and the 650V / 1200V CoolSiC™ Schottky diode.

Modular solutions are the best fit for chargers in the 50kW to 350kW power range.

For the Vienna rectifier in the PFC stage and the converter stage in the DC/DC stage, Infineon recommends the CoolSiC™ MOSFETs in an Easy package. The EconoPACK™ and EconoDUAL™ families are also ideal for this application.

The following table lists some of Infineon's product highlights:

Product family

Product name

Benefits

TRENCHSTOP™ 5 H5

IKW75N65EH5

• Best-in-class efficiency, resulting in lower junction and case temperatures


• Higher device reliability


• 50V increase in the bus voltage without compromising on reliability


• Designs with higher power densities

CoolSiC™ Schottky Diode

IDW40G65C5


IDH20G65C6


IDW40G120C5B

• Improved system efficiency over all load conditions


• Increased system power density


• Reduced cooling requirements and increased system reliability


• Enables extremely fast switching


• Easy and effective match with CoolMOS™ 7 families

CoolMOS™ CSFD


CoolMOS™ P7


CoolMOS™ CFD7

IPW60R037CSFD


IPW60R037P7


IPW60R018CFD7

• Best fit efficiency for EV charging applications


• Enabling higher power densities


• Highest reliability levels


• The right RDS(on) package combination can be selected


 

EasyDUAL™ 2B with CoolSiC™ MOSFET

FF6MR12W2M1_B11


FF8MR12W2M1_B11

• Highest efficiency for reduced cooling effort


• Longer lifetime and higher reliability


• Higher-frequency operation


• Reduced system costs


• Increased power density


• Reduced system complexity


• Ease of design and implementation


 

EconoPACK™ 4

FS200R12PT4

• More cost effective than using 3 x 34mm modules / 62mm modules


• Allows more compact inverters than using 3 x 34mm / 3 x 62mm modules


 

EconoDUAL™ 3

FF225R12ME4

• Increased output power with the same module current


• Reduced cooling effort with optimized thermal resistance to the heatsink


• Reduced system costs, e.g. for the heatsink, PCB, housing, and mounting the module


• One module fits several applications


 

Drive and control

Every power-switch needs a gate driver IC. Getting the right driver is vital for designing efficient EV charging solutions.

Infineon offers a broad range of driver solutions for power MOSFETs and IGBTs. Infineon's EiceDRIVER™ also gets the best performance out of CoolSiC™ MOSFETs.

Find out which gate driver is the best match for the different Infineon power switches:

Product family

Product name

Benefits

Suitable IGBT / MOSFET / CoolSiC™ MOSFET

1EDI EiceDRIVER™ compact

1EDI40I12AH


1EDI60I12AH


1EDI20H12AH


1EDI60H12AH

• Best-in-class common mode transient immunity (CMTI): 100kV/µs


• Wide input operating range (3…17V)


• No voltage/signal adaptation required between µC and driver

• TRENCHSTOP™ 5 H5


• EasyDUAL™ with CoolSiC™ MOSFET

1ED/2ED EiceDRIVER™ enhanced

1ED020I12-B2


1ED020I12-F2


2ED020I12-F2

• Best-in-class common mode transient immunity (CMTI): 100kV/µs


• Comprehensive, integrated protection feature set

• CoolMOS™ P7


• CoolMOS™ CFD7


• TRENCHSTOP™ 5 H5


• EasyDUAL™ with CoolSiC™ MOSFET

2Edi EiceDRIVER™ family

2EDS8265H


2EDF7175F


2EDF7275F


2EDS8165H

• Enabling higher system efficiency and higher power density


• Long-term cost benefits, integration and mass production capabilities


• Extending end-product lifetime by improving safe operation of power switches in normal and abnormal grid conditions


• Lower EMI & simplified safety approval

• CoolMOS™ P7


• CoolMOS™ CFD7


• TRENCHSTOP™ 5 H5


• EasyDUAL™ with CoolSiC™ MOSFET


Available gate driver evaluation boards:

EVAL-1ED020I12-B2

EVAL-2ED020I12-F2

EVAL-1EDI60I12AF

For more information on Infineon gate driver ICs, check out the gate driver application matrix and the selection guide for industrial galvanic isolated gate driver ICs.

Infineon has bundled its wealth of experience in microcontroller design to offer a broad portfolio that covers a wide range of industrial applications such as DC EV charging.

The portfolio is based on:

  • The XMC™ family for real-time critical applications that require an industry-standard core
    For DC EV charging, Infineon offers the XMC4000 family powered by ARM® Cortex®-M4 with a built-in DSP instruction set. The single-precision floating-point unit, direct memory access (DMA) feature and memory protection unit (MPU) are state-of-the-art for all devices
  • Infineon recommends the AURIX™ family for applications that require more performance, connectivity, safety and security

Secure authentication & communication

The OPTIGA™ security solution family is designed for easy integration into embedded systems to protect the confidentiality, integrity and authenticity of information and devices.

OPTIGA™ Trust B includes turnkey products for smaller platforms and programmable solutions, supporting all embedded authentication and brand protection needs as well as a host of other security applications.

OPTIGA™ TPM (Trusted Platform Module) offers a broad portfolio of standardized security controllers to protect the integrity and authenticity of embedded devices and systems.

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