Common Types of Charging Modules

With the rapid development of the electric vehicle (EV) industry, advancements in charging module technology directly impact charging efficiency, safety, and application adaptability. This article categorizes mainstream charging modules based on three key dimensions: power density, protection class, and power conversion topology, outlining their respective features.

Classification by Power Density

 ● Low-to-Medium Power Modules (20-40kW)  

 Technical Positioning: Early mainstream solution for basic fast charging.  
 Key Parameters: Air-cooled, silicon-based IGBT (high switching loss), 95%-97% efficiency, compatible with 400V platforms.  
 Applications: Early community/shopping mall charging piles, slow charging for compact EVs.  
 Limitations: Not compatible with 800V ultra-fast charging.  

 ● High-Power Modules (50-60kW)  

 Technical Upgrades: Liquid cooling replaces air cooling; partial adoption of SiC devices (50% lower switching loss).  
 Key Parameters: 97%-98% efficiency, supports 800V platforms.  
 Applications: Ultra-fast charging piles (e.g., Huawei/Xpeng), heavy-duty truck charging stations.  
 Advantages: Compact size (40% higher power density), compatible with high-voltage EV models.  

 ● Ultra-High-Power Modules (80-120kW)

 Breakthroughs: Full liquid cooling + complete SiC adoption.  
 Key Parameters: >98% efficiency, supports 1500Vdc (future-proof for high-voltage platforms).  
 Applications: Megawatt-level ultra-fast stations (e.g., heavy-duty truck battery swap stations), next-gen 1200V EVs.  
 Trend: Expected to become the standard for ultra-fast stations post-2025, alongside 800V EV adoption.  

Classification by Protection Class

 ● IP20 (Obsolete)  

 No dust/water protection; only for indoor use. Banned for outdoor applications post-2018 under new regulations.  

 ● IP54 (Mainstream)  

 Limited dust/water splash resistance; features independent air ducts and conformal coating. Ideal for semi-outdoor use (e.g., underground parking), with  20%-30% lower cost than IP65.  

 ● IP65 (Premium)  

 Fully dustproof and resistant to low-pressure water jets; sealed metal housing + hermetic cooling. Designed for harsh environments (e.g., ports, deserts), with 50% longer lifespan (up to 10 years).  

Classification by Power Conversion Topology

 ● AC/DC Modules: The "Bridge" from Grid to Battery

 Converts AC to high-voltage DC, incorporating rectification, PFC (power factor 0.99), and optional isolation. Input: 380V/220V; output: 200-1000Vdc. Used in DC fast-charging piles.  

 ● DC/DC Modules: The "Regulator" for DC Systems  

 Adjusts DC voltage levels; topologies include non-isolated (Buck/Boost) and isolated (LLC). Efficiency >98%, fast dynamic response (100A/ms). Applications: onboard low-voltage supply, PV-storage-charge systems, ultra-fast charging power distribution.  

 Module selection requires balancing power needs (high-power = liquid cooling + SiC), environmental conditions (harsh environments = IP65), and system architecture (PV-storage-charge systems rely on DC/DC). Future competitiveness will hinge on ultra-high power, robust protection, and high-efficiency modules.