Classification by Current Type
AC/DC Charging Module
Application: Used in unidirectional charging stations; the most common and widely used type of charging module.
Principle: The primary function of the AC/DC charging module is to convert the incoming alternating current (AC) into direct current (DC) suitable for charging electric vehicle batteries. It utilizes a rectifier circuit to convert AC into pulsating DC, which is then processed through filtering and voltage regulation to obtain stable DC output. For example, in common charging stations, when an electric vehicle is connected, 220V or 380V AC mains supply enters the charging module, which processes it through complex internal circuits to output DC voltage and current that meet the charging requirements of different battery types (e.g., lithium-ion batteries).
Features:
Safety: Equipped with multiple protection functions such as overcurrent, overvoltage, undervoltage, and leakage protection. For instance, in the case of overcurrent protection, if the current exceeds the set value during charging, the module automatically disconnects the circuit to prevent damage to the battery and charging equipment.
Compatibility: Able to accommodate the charging needs of different brands and models of electric vehicles. This is because different electric vehicle battery management systems (BMS) have varying requirements for charging voltage and current, allowing the AC/DC charging module to adjust output parameters within a certain range to meet these needs.
DC/DC Charging Module
Application: Used for charging batteries from solar photovoltaic sources and for battery-to-vehicle charging, commonly found in solar storage projects or storage charging projects.
Principle: The DC/DC charging module primarily converts between different DC voltage levels. In automotive applications, it can charge a low-voltage auxiliary battery from a high-voltage battery pack or transfer energy between DC power sources of different voltage levels. It is based on switch-mode power supply technology, controlling the switching transistors to convert high-voltage DC input into low-voltage DC suitable for the load.
Features:
Precise Voltage Regulation: Can accurately adjust the output voltage based on different load requirements. For example, when charging a 12V auxiliary battery in a vehicle, it can precisely convert the high-voltage battery pack's hundreds of volts to a stable voltage around 12V.
High Energy Conversion Efficiency: Offers high energy conversion efficiency, minimizing energy losses during the conversion process, which is crucial for enhancing the overall energy system efficiency of the vehicle.
Bidirectional V2G Charging Module
Application: Supports vehicle-to-grid (V2G) interactions and bidirectional charging needs for energy stations.
Principle: The bidirectional V2G charging module enables bidirectional energy flow. During charging, it functions like a regular charging module, converting the grid's AC into DC for charging the vehicle's battery; during discharging, it converts the DC from the vehicle's battery back into AC to feed into the grid. This process involves complex power electronic conversion technologies, including inverter circuits, to achieve bidirectional energy conversion.
Features:
Bidirectional Power Flow Control: Precisely controls the bidirectional flow of energy, ensuring stable operation under different conditions (e.g., charging, discharging, grid demand fluctuations). For instance, during peak load times, it can return energy from the vehicle's battery to the grid at an appropriate power level according to grid dispatch requirements.
Grid Interaction Coordination: Can effectively communicate and interact with the grid, adhering to relevant standards and protocols. This allows it to automatically adjust its operating mode based on the grid's status (e.g., voltage, frequency).
Classification by Power Level
Common power levels include 3kW, 7.5kW, 15kW, 20kW, 30kW, 40kW, 50kW, etc. The higher the power, the faster the charging speed. Currently, the mainstream charging module power levels in the market are 30kW and 40kW, with future developments aimed at higher powers such as 60kW and 80kW.
Classification by Application Scenario
Low-voltage Modules: Suitable for low-power charging scenarios.
High-voltage Modules: Suitable for high-power charging scenarios, such as fast charging stations.
Forklift-specific Modules: Designed specifically for electric forklifts and other industrial equipment.
Application Scenarios
1. Electric Vehicle Chargers
Home Charging: For private electric vehicle users, the charging module is the core component of home charging stations, allowing owners to charge their vehicles overnight to meet daily commuting needs. Depending on the module's power, charging times vary. For instance, using a 7kW charging module, it takes about 8 to 9 hours to fully charge a vehicle with a 400 km range and a 60 kWh battery.
Public Charging Stations: In urban public charging stations, charging modules provide charging services for passing electric vehicles, often with higher power levels (e.g., 30kW, 40kW or higher) to enable quick charging and reduce waiting times for owners.
2. Photovoltaic Power Generation Systems
Integrated Solar Storage Charging Projects: In solar storage charging facilities, charging modules connect solar panels and electric vehicle batteries. During the day, part of the direct current generated by the solar panels can directly charge the electric vehicle (using the DC/DC charging module), while another part can be stored in energy storage batteries (also relying on charging modules for conversion and management), achieving efficient energy utilization.
3. Energy Storage Systems
Grid Energy Storage: In grid energy storage applications, charging modules convert grid energy into DC suitable for battery storage. During peak load times, energy from storage batteries can be fed back into the grid through inverters, helping to balance load demand.
Distributed Energy Storage: For distributed energy storage scenarios, such as community storage or factory storage, charging modules manage the charge and discharge processes of batteries, improving energy self-sufficiency and stability.
4. Industrial Equipment Charging
Electric Forklift Charging: Charging modules designed specifically for electric forklifts consider the working characteristics of forklifts, such as frequent starts and stops and high load operations, providing stable and efficient charging services. Forklifts can charge during work breaks or overnight.
Other Industrial Electric Equipment: Equipment like electric cranes and electric pallet trucks also require charging modules to supply adequate energy, ensuring normal operation.
5. Commercial Charging Facilities
Shopping Malls and Hotels: Charging stations set up in commercial venues provide charging services for electric vehicle owners who come to shop or stay, enhancing convenience and improving the service level and attractiveness of these venues.
Office Building Charging: Charging stations in office building parking lots allow employees to conveniently charge their electric vehicles, meeting their daily commuting needs.
