Fraunhofer ISE Develops Medium-Voltage System for Fast-Charging Stations, Enhancing Flexibility and Cost Efficiency

Credit: Fraunhofer ISE

Fraunhofer ISE has collaborated with industrial partners to develop a medium-voltage system designed for future fast-charging stations, which will be capable of handling peak loads of several megawatts. The innovative system promises increased flexibility and cost reductions for high-power charging infrastructure, positioning it as a future solution for large-scale charging networks.

The project, dubbed ‘MS-Tankstelle,’ focuses on raising the voltage level on the charging station side to reduce material use and the associated costs of high-power charging stations. Currently, high-power chargers operate using lower voltages, but the Fraunhofer ISE team is targeting larger charging stations. “In future, petrol stations will need around 15 to 25 charging points instead of eight pumps to serve the same number of vehicles in the same amount of time,” stated the institute. As charging times are longer compared to traditional refueling, the need for more charging points in future stations becomes critical.

With parallel fast-charging at multiple points, the required power ranges from 1.5 to 3.5 megawatts, which exceeds the capacity of current low-voltage grids. The project proposes a shift to a medium-voltage network, which operates with a 1,500 VDC rectifier. This approach allows more power to be transmitted without the need for thicker cables, reducing costs and material usage. Fraunhofer ISE also mentioned that the 1,500 V was chosen because it marks the threshold between low-voltage and higher standards, with plans to extend the voltage in future iterations.

The system includes a newly developed, electrically isolated converter that links the 1,500-volt network to the vehicle battery, enabling a charging output of up to 350 kW. The converter, designed by Fraunhofer ISE in partnership with Sumida Components & Modules GmbH, Infineon Technologies AG, and AEG Powersolutions GmbH, utilizes silicon carbide semiconductors to improve efficiency. The system supports compatibility with CCS1 and CCS2 standards and aims to meet future demands, including the Megawatt Charging System (MCS) for electric trucks.

According to Andreas Hensel, Group Manager at Fraunhofer ISE, the system developed “finds applications not only in charging stations but also for its integration in renewable hybrid power plants or stationary battery storage systems.” This versatility highlights the potential for the system to play a significant role in energy infrastructure beyond just vehicle charging.

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