Design, Development & Manufacturing of Flexible Standard Fast EV Charger

The world is transiting from mechanical to electro-mechanical in the field of moving and dynamical systems.The key technologies like modern power electronics ,digital processor/controllers are enabling all this from static drives in industries to high power actuators in space or in house automation vacuum robotic system to high power electric vehicle for road transportation. Electric mobility is now becoming reality of near future. Vehicle manufacturers and policy makers are boosting their attention and actions related to electric vehicles(EVs).Now, there’s been a renewal of this technology, especially towards the end of the 20th century. To reduce the impact on the climate, the industry is experiencing a shift from internal combustion engine (ICE) vehicles to electric vehicles.

ICE-based vehicles operate on oil, an increasingly scarce resource that heavily pollutes the environment and is a major contributor to climate change.In addition to the direct incentives and measures to promote PHEVs & HEVs adoption, there are other factors that are reinforcing the transition to e−mobility. But there have been underlying roadblocks that have hampered the evolution into the new model, the most prominent ones being: range anxiety, the price of EV vehicles, and finally, the charging times of the batteries compared to filling the tank of a conventional vehicle. Range anxiety can be overcome by the development of hybrid electric vehicles (HEVs) and plug-in hybrids (PHEVs) vehicles. The other alternative is to replace it with higher energy density batteries.

The last remaining hurdle is the charging time, where slow (up to max 22kW effectively) and fast systems (22–400kW and targeting above) coexist. Slow charging systems are already relatively widely available in households, public parking, and workplace parking. However, fast-charging systems are mostly available publicly, in commercial areas, or in charging stations as they require dedicated electrical infrastructure.

At the highest power rating of slow charging, the systems can provide 100 km additional range in approximately 50−60 minutes, but even these cannot be deployed at households easily. At the lower power end, 1.4 –3.7kW rates are possible at households and privately when using a dedicated cable directly connected to the standard socket-outlet but take around 5 hours (at 3.7kW) to add 100 km of range.

On the contrary, fast-charging systems can deliver this range in less than 10-minutes. For a significant share of drivers and use cases, slow charging might be a feasible solution, but clearly, not for everyone or every situation. 

EVs are well suited to help solve air pollution issues. Moreover, EVs are driving advances in battery technology –a key issue for industrial competitiveness in the transition to clean energy. EV fleets are expanding at a fast pace in several of the world’s largest vehicle markets. The costs of batteries and EVs are dropping. Charging infrastructure is expanding. This progress promotes electrification of transport modes such as two/three-wheelers, light-duty vehicles (LDVs) (cars and vans), taxis and shared vehicles, buses, and heavy-duty vehicles with short range requirements such as urban deliveries. Manufacturers are continuing to expand the number of EV models available to customers.

There were more than 10 million electric cars on the world’s roads at the end of 2021, following a decade of rapid growth. Electric car registrations increased by 41% in 2020, despite the pandemic-related worldwide downturn in car sales in which global car sales dropped 16%. Around 3 million electric cars were sold globally (a 4.6% sales share), and Europe overtook the People’s Republic of China (“China”) as the world’s largest electric vehicle (EV) market for the first time. Electric bus and truck registrations also expanded in major markets, reaching global stocks of 6,00,000 and 31,000 respectively.

The near-term outlook for EV sales is bright. In the first-quarter of 2021, global electric car sales rose by around 140% compared to the same period in 2020, driven by sales in China of around 500 000 vehicles and in Europe of around 450 000. US sales more than doubled relative to the first-quarter of 2020, albeit from a much lower base.

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