High Power Charging – The technology for fast charging stations

Highway service area with HPC charging stations

Fast charging stations for electric vehicles

100 km driving range available in just 3 to 5 minutes: with our High Power Charging technology, long charging times are a thing of the past for electric vehicles.

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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
    Areas of application for HPC charging technology

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

Innovator award for High Power Charging technology –
Conferred by laureate Dr Wladimir Klitschko

Phoenix Contact wins the “2019 Innovator of the Year” award for its High Power Charging technology  

Dirk Moseke, Robert Ewendt, and Michael Heinemann from Phoenix Contact with Dr Wladimir Klitschko and DDW General Manager Michael Oelmann (photo: Uwe Erensmann/@uepress)

Since Thursday, May 9, 2019, it has been official: Phoenix Contact and its High Power Charging technology is the “2019 Innovator of the Year”. Michael Heinemann, CEO of Phoenix Contact E-Mobility, officially accepted the Business Award from "Die Deutsche Wirtschaft" (DDW), the German economy information portal, at a ceremony in Düsseldorf: "We feel honored that the jury selected us. And we simply did not expect to receive the People’s Choice Award on top of that."

A total of 20 companies received awards but only three were given the People’s Choice Award, which was decided by a vote among the readership. The award was personally conferred by laureate Dr Wladimir Klitschko. More information and photographs from the award ceremony are available in our LinkedIn article.

Long driving range, extremely short charging time –
Fast charging stations with High Power Charging technology

High Power Charging connectors for short charging times  

High Power Charging enables extremely short charging times for electric vehicles

With High Power Charging, the fast charging of electric vehicles at EV charging stations will provide significant driving range and will become comparable to refueling with gas. This advanced charging technology makes it possible to charge electric vehicle batteries with a charging power of 500,000 watts (half a megawatt) during a brief coffee break. Our High Power Charging connectors 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.

The next-generation EV charging station – Fast installation and high-level maintainability

EV charging stations that are easy to install and maintain  

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

Those planning the charging infrastructure and manufacturing the EV 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 fast charging station with High Power Charging technology is therefore practically the same as that of conventional EV charging stations.

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 charging connector and charging cable do not overheat due to the high charging currents. Thanks to the use of an environmentally friendly water-glycol mixture 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 charging connectors is easy to maintain.

Charging cables at public EV charging stations are subject to great mechanical strain, since they may be dropped or even driven over, for example. The mating face is subject to the highest strain. 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 quick and easy, minimizing downtimes for the charging stations and ensuring that the costly replacement of the entire charging cable is not necessary.

Intelligent charging connector with real-time analysis data transmission

There is even more intelligent technology installed in the charging connector interior: the integrated sensor technology provides information on the overall status of the High Power Charging connector, its usage and wear, as well as further analysis data. All of this information is stored in the charging 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 fast charging station being approved.

The High Power Charging connector in detail

Learn more about the above-listed features of our High Power Charging connector. Simply click on the hotspots to find out more.

 
Interior view of the High Power Charging connector

Further information on the High Power Charging system components, cooling system, and technical data is available in our technology section.

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

Fast charging connector with intelligent sensor technology  

Our engineers overcame several challenges while developing the charging connector

Our High Power Charging technology 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 fast charging connector was how to design both the cross section of the charging cable and the size and weight of the charging 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 e-mobility networks

CharIN and NPM logos  

We are members of CharIN and NPM

Phoenix Contact has established itself as one of the leading market drivers in the field of e-mobility and the fast charging of electric vehicles – not just through products and new technologies, but also through its involvement in establishing e-mobility standards. Alongside leading German automobile 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 the fast charging of electric vehicles. 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 Germany's 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 National Platform for Electric Mobility (NPE). In this role, he was instrumental in shaping international standards and regulations in the field of e-mobility. He will continue and develop these activities in the new NPM Working Group.

E-mobility today and in the future

E-mobility is already suitable for everyday use  

The Wave Trophy proves e-mobility is suitable for everyday use

E-mobility is becoming increasingly important, not just nationally, but throughout the world. Furthermore, e-mobility 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 our High Power Charging technology for EV charging stations, 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 e-mobility, because if it becomes just as practical and fast as refueling conventional 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 fast charging stations featuring High Power Charging technology.

E-mobility and charging stations for electric vehicles 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 e-mobility – not least through High Power Charging and all future developments in e-mobility.

Phoenix Contact has already proved that e-mobility 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

Are you a fast 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 create suitable components for your fast charging station that are tailored to your application.

PHOENIX CONTACT Ltd

Unit 15C, 906-930 Great South Road, Penrose
Auckland 1061
New Zealand

Phone: 0508 474 636
Toll Free (Local)
09 950 8495

Service

Faster than expected

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.

More on this topic

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