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E-mobility for the Future: Storage-based 320 kW Fast "High Power Charging" Solution for the Limited-power Low-voltage Grid

The new "HPC-Booster" battery storage system by ADS-TEC ensures that charging times are as short as possible, even on the low-voltage grid, in cooperation with fast charging stations. ADS-TEC is nominated for this year’s ees AWARD, which is presented by the organizers of ees Europe in cooperation with international industry associations and is devoted to the electrical energy storage solutions behind the clean energy of tomorrow.

 

The success of e-mobility depends crucially on whether an effective charging infrastructure exists. Whoever is passing by does not have time to wait for hours. High electrical power is required for short charging times. It is not always possible and economical to expand the grid at all points to such an extent that this high power is available. In many cases, it makes more sense to first slowly fill the storage system at the available grid connection point, the energy contents of which are then released into the vehicle in one go and using high electrical power, which is comparable with a toilet cistern.

The same applies to fast charging within the low-voltage grid using the new battery-based HPC solution by ADS-TEC. The system offers high charging capacity (up to 320 kW) which provides a range of several hundred kilometres in just a few minutes. Such high electrical power is otherwise only achieved with a connection to a medium-voltage system. This means that the HPC-Booster can be used to set up a comprehensive fast charging infrastructure in a timely manner and to avoid expensive and time-consuming grid upgrades in many places.

The demand for electric vehicle charging stations will be different than for conventional mobility using diesel and petrol. As people will also collect and consume energy themselves in the future, a charging infrastructure will be created wherever vehicles are parked for short or long periods of time before continuing their journey. This includes homes, residential areas and workplaces, as well as destinations such as supermarkets, restaurants, museums, event venues, hotels, conventional petrol stations, etc. These stations will always be found where fast charging is required and there is only limited grid access.

"HPC-Booster" battery system

The HPC-Booster includes the battery storage system, power electronics to the grid (bidirectional battery inverter) and to the charging point, air conditioning, controller and energy management. It is currently the most compact of its kind in the world and has been designed in cube format with a surface area of only 1.2 m x 1.2 m and a volume of less than 2.5 m³. Space is crucial and very expensive, especially in major cities. The distance to the grid connection can be 200 metres and the storage system and charging stations can be placed up to 100 metres apart. Compared with expanding to a medium-voltage system, this solution requires no space for the transformer, switchgear and fast charger. Plus the costs that are saved from construction cost subsidies, 10 kV transformer system with counter and power meter, including installation costs and a performance price for below and above 7,000 full load hours per year, should be taken into account.

Previous fast charging systems were often designed for connection to the high-power, medium-voltage grid. The HPC-Booster, on the other hand, is designed for connection to the conventional 400 volt distribution grid with connection in the range of 20 to 110 kVA. The integrated battery modules with their extremely high energy content of up to 140 kWh are dynamically recharged according to the available grid capacity using an intelligent controller. In doing so, grid services can be provided decentrally within the network or by management. With the available power and capacity, anything is conceivable that makes sense and is permitted under regulations: from connection capacity limitation to arbitrage and the optimisation of private consumption up to connected control energy.

The HPC-Booster has two power electronic units with 160 kW charging power each to connect up to two dispensers. These can be coupled, if required, so that up to 320 kW DC power is available at one charging point. The integrated high-performance climate concept controls the temperature level of the battery modules, power electronics and the charging technology.

The core technology is based on ADS-TEC standards (BMS, EMS, control, safety and more). The technology is special due to its modularity and very high energy density. Special thermal management, the highest safety precautions and a complex determination of SOC and SOH are further topics that bring decisive added value.

The charging system is designed for all voltage levels of on-board traction power systems and is therefore backward compatible for existing e-vehicles from 200 V DC upwards and ensures a bright future for vehicle generations up to 920 V DC. Even though only a few vehicle types, such as the Porsche Taycan, can be charged with 320 kW for the time being, more and more manufacturers will follow suit in the future in order to charge vehicles as quickly as possible.

The entire charging system, which consists of the battery system (HPC-Booster) and one or two charging stations (HPC Dispenser), complies with current standards, both in Europe and in the USA, and can be easily integrated into the existing 400 V distribution grid. A great deal of effort is made to fully test and certify the HPC system in accredited test laboratories in accordance with the current charging standards and regulations. Safety is the top priority, considering that 320 kW corresponds to the average output of around 350 family homes. Furthermore, it has low noise emissions, which makes it flexible in terms of location. In addition to the sophisticated technical equipment, it is prestigious and the high quality lives up to the lifestyle expectations of the electromobility community. Porsche is both – a development partner and one of the first major customers.

 

Karl Knezar

Head of Sales Charging Infrastructure

ADS-TEC Energy GmbH


The ees International Magazine is specialized on the future-oriented market of electrical energy storage systems, not only from a technological-, but also a financial and application-oriented point-of-view. In cooperation with ees Global, the ees International Magazine informs the energy industry about current progress and the latest market innovations.
Contact: Xenia Zoller - zoller(at)ees-magazine.com