|The NLG6 22 kW on-board charger. Click to enlarge.|
Starting this month, BRUSA Elektronik AG will be the first company to produce an on-board battery charger for electric vehicles that is capable of operating on a three-phase current with a power of up to 22 kW. As a result, the fast charger will be able to fully charge the pack in a current typical battery-electric car in less than one hour without a special DC infrastructure.
Cars from a major European car manufacturer equipped with this charger will be available to customers for the first time by end of this year.
Two factors determine the charging time of an electric car: the size of the battery pack and the power of the charger. While the battery pack size varies depending on the type of electric car, the on-board chargers in Europe normally operate with a maximum power of 3.7 kW. Thus the charging times range typically between 6-8 hours.
Until now, fast charging with the power of 22 kW and above was only possible by using off-board DC charging infrastructure requiring more extensive space and expense. In its new fast charger NLG6, BRUSA Elektronik AG has successfully integrated the required power electronics in a single and compact device that moves the fast charging infrastructure on-board electric cars of any size.
The fast charger itself requires no cost-intensive off-board infrastructure but can generally be used at all three-phase power supplies. Modern house connections and most public charging points in Europe are already equipped with the required power supply of 400 volt and 32 amps. The fast charger can also be used with lower rated power sources (e.g. 3.7 kW).
It was a big challenge to increase the power of our chargers by six times and not overly exceed the dimensions of standard chargers. We believe that through the immense reduction of the charging time, the acceptance of emobility will noticeably change.—Philipp Matt, Head of Engineering at BRUSA.
Features of the NLG6 include:
- Active HV interlock monitoring in compliance with LV 123
- Control Pilot and Proximity Detection in compliance with IEC 61851
- 4 x output driver (12 V/5A) for mechanical interlock
- Evaluation of external PT1000 resistance thermometers
- 3 x PWM output signals (12 V/ 20 mA) for control of external LED
- Compatible with the new “Combined Charging System” (IEC 61851)
The fast charger NLG6 also comes with safety measures including the principle of galvanic isolation to ensure maximum safety for the user in case of a hazard, such as damaged high-voltage connections. Because BRUSA chargers do not harness existing components such as the controller’s power electronics or parts of the motor itself to charge the battery as seen in other applications, a definite separation between the car and the grid is provided. As a result of this, all safety-related standards and EMC requirements from both worlds are met.
The NLG6 has successfully been tested by the VDE association on its CE conformity and behaves towards ground fault protection devices according to regulations.
The power density of 1.9 kW/kg makes the new fast charger one of the most efficient devices on the market. Using PLC (power line communication) technology, the fast charger is able to communicate through the charging cable and thus enabling various functionalities such as internet connectivity (e.g. when mobile network is not available) or intelligent charging (Smart Charge Communication according to ISO15118).
To be able to compensate for the increased availability of renewable energy sources and decentralized power production, grid stabilizing measures will gain importance in the future. The NLG6 is well prepared to bring stability into the grid with intelligent features such as idle and peak power regulation and bidirectional operation, the company notes.
BRUSA Elektronik AG is in its final preparations to start the large-scale production of the new fast charger. Cars equipped with the BRUSA fast charger will be available to the customers in October 2012.