High Power Charging – The charging station of tomorrow

Highway service area with HPC charging stations

Rapid charging stations for electric vehicles

With High Power Charging, long electric vehicle charging times at electric charging stations are a thing of the past. The result is electromobility that is suitable for everyday use.

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  • Technology
    High Power Charging Technology

    Phoenix Contact's intelligent HPC technology is based on an active cooling system that makes charging currents of up to 500 A possible, without compromising on safety or manageability.

  • Areas of application
    HPC charging technology areas of application

    Phoenix Contact's HPC system can be used anywhere where electric vehicle drivers are short on time, particularly on highways and at major traffic interchanges.

High Power Charging is a charging technology developed by Phoenix Contact and installed in charging stations for electric vehicles. With this technology, electric vehicle batteries can be charged for a distance of 100 kilometers in just three to five minutes. The Phoenix Contact High Power Charging technology is setting a milestone for the future of electromobility, making electric vehicle charging suitable for everyday use – and then some. The idea of charging electric vehicles with 500 amps at a service area will become quite commonplace.

Long distances, extremely short charging times – with High Power Charging stations

High Power Charging connectors for short charging times  

High Power Charging enables extremely short charging times for electric vehicles

With High Power Charging , rapidly charging electric vehicles for significant distances will become comparable to filling a standard diesel or petrol vehicle. This advanced charging technology makes it possible to charge electric car batteries with a charging power of 500,000 watts (half a megawatt) during a brief coffee break. High Power Charging stations also conform with the CCS standard, which means they are backward-compatible with electric vehicles that do not support the latest technology. The Combined Charging System (CCS) is already established as the charging standard for Europe and America.

Electric charging stations of the next generation: Fast installation and high-level maintainability

Those planning the charging infrastructure and manufacturing the electric vehicle charging stations of tomorrow attach particular importance to the corresponding technology being simple to set up and fast to install. Right at the start of the High Power Charging development phase, Phoenix Contact placed the spotlight on achieving the fastest possible installation times. To this end, and among other innovations, a special cable feed-through was developed which enables the charging cable to be mounted on the charging station conveniently and easily. The setup time of a High Power Charging station is therefore practically the same as that of conventional electric charging stations.

Electric charging stations that are easy to install and maintain  

The High Power Charging system is particularly easy to install and maintain

The technology is just as user-friendly to maintain as it is to install. In contrast to conventional charging stations, High Power Charging stations are equipped with intelligent fluid cooling to ensure that the vehicle connector and charging cable do not overheat due to the high charging currents. Thanks to the use of an environmentally sound mixture of water and glycol as the coolant, servicing of the cooling circuit is comparatively simple. In contrast to maintenance-intensive closed systems with oil cooling, the semi-open system necessary for our vehicle connectors is easy to maintain.

Charging cables at public electric charging stations are subject to great mechanical strain, since they may be dropped or even driven over, for example. Here, the mating face is affected the most. The High Power Charging connector from Phoenix Contact has therefore been designed such that the mating face frame and power contacts can be replaced quickly. This makes repairs easy and quick, minimizing downtimes for the charging stations and ensuring that the costly replacement of the entire charging cable is not necessary.

Intelligent vehicle connector with real-time analysis data transmission

There is even more intelligent technology installed in the vehicle connector interior: the integrated sensor technology provides information on the overall status of the High Power Charging connector, its consumption and wear, as well as further analysis data. All of this information is stored in the vehicle connector and also transmitted to the operator in real time. To ensure the highest level of safety, the system is also monitored constantly for overheating and any potential coolant leaks. Naturally, the High Power Charging cable is CE-certified and satisfies the relevant standards. Therefore, on the cable side, there is nothing to prevent the charging station being approved.

From the Combined Charging System (CCS) to High Power Charging

Rapid charging connector with intelligent sensor technology  

Our engineers overcame several challenges while developing the vehicle connector

High Power Charging is based on the Combined Charging System – CCS – the standard for which has already been developed by Phoenix Contact in cooperation with the automobile industry to drive the technology forward. One of the greatest challenges faced when developing the rapid charging vehicle connector was how to design both the cross section of the charging cable and the size and weight of the vehicle connector to be as practical as possible. This problem could only be overcome by developing an intelligent and efficient cooling system, as well as designing a carefully considered cable.

Furthermore, the connectors are fitted with silver-plated contacts and a contact carrier that, thanks to its excellent thermal conductivity, also acts as a heatsink. As a result, a particularly high level of stability and exceptional cooling performance are achieved at the same time.

Phoenix Contact – The driving force behind establishing standards and a founding member of electromobility networks

Phoenix Contact has established itself as one of the leading market drivers in the field of electromobility and rapid electric vehicle charging – not just through products and new technologies, but also through its involvement in establishing electromobility standards. Alongside leading German car manufacturers and the TÜV Süd certification body, Phoenix Contact is one of the founding members of the CharIN (Charging Interface Initiative) association, which drives forward and promotes electric vehicle rapid charging. The objective of CharIN is to establish the Combined Charging System (CCS) as the global standard for electric vehicles.

Phoenix Contact is also represented in the German National Platform for The Future of Mobility (NPM), recently founded by General Manager Roland Bent. Within this platform, he is the Chairman of Working Group 6 (AG 6), focusing on regulation, standardization, certification, and approval. Prior to this, he was Vice Chairman of Working Group 4 (AG 4) within the predecessor organization, the German National Platform for Electromobility (NPE). In this role, he was instrumental in shaping international standards and regulations in the field of electromobility. He will continue and develop these activities in the new NPM Working Group.

Electromobility today and in the future

Electromobility is already suitable for everyday use  

The Wave Trophy proves electromobility is suitable for everyday use

Electromobility is becoming increasingly important, not just nationally, but throughout the world. Furthermore, electromobility is the environmentally sound and sustainable future of mobility as we know it today. To achieve this goal, many new approaches and innovative technologies are needed in the automotive and electricity industries. Not least for this reason, the goal of the German Federal Government and industry is to establish Germany as the leading market worldwide, and to actively shape the sea change that is underway in mobility to create a global benchmark.

With High Power Charging technology from Phoenix Contact, another successful step has been taken towards making battery-powered vehicles suitable for everyday use. The ability to charge electric vehicles rapidly will shape the future of electromobility, because if it becomes just as practical and fast as filling conventional petrol or diesel vehicles, it will become permanently accepted by consumers. Charging stations for electric vehicles are currently being heavily promoted by the EU and the German Federal Government, including the construction of High Power Charging electric charging stations.

Electromobility and charging stations for electric cars will face many challenges in the future that must be mastered successfully with innovative ideas, technologies, and products. Phoenix Contact will follow this path together with the German Federal Government, representatives of the automotive industry, charging infrastructure operators, and other partners, and actively help to shape the future of electric mobility – not least through High Power Charging and all future developments in electromobility.

Phoenix Contact has already proved that electromobility is suitable for everyday use through the many times it has successfully taken part in the Wave Trophy, the largest electric vehicle rally in the world.

Your individual High Power Charging solution

Your individual High Power Charging solution  

The first High Power Charging stations at the Jettingen-Scheppach service area

Are you a rapid charging station manufacturer or charging station planner interested in our High Power Charging technology?

Thanks to the modular design of our High Power Charging system, it can be used in a variety of applications – meaning that nothing stands in the way of developing your charging infrastructure nationwide.

We will be happy to help you, and will put together the right components, specifically tailored to your application for your individual High Power Charging solution.

PHOENIX CONTACT Ltd

Halesfield 13
Telford
Shropshire
TF7 4PG
0845 881 2222

Calls will cost 2p/min plus your telephone company’s access charge.

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You think charging an electric car takes hours? These times are over, thanks to HPC.


How does High Power Charging work?

Learn how the technology in the High Power Charging vehicle connector works.

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