Speeding up the e-mobility transition with fast charging

Fast chargers are critical in supporting long-distance travel for battery electric vehicles and alleviating range anxiety. This new rapid charging solution is speeding up the transition.

Fast chargers enable quick recharging of battery electric vehicles (BEVs) and, as the adoption of BEVs grows, the availability of fast charging infrastructure is becoming increasingly important. Recent figures from the European Automobile Manufacturers’ Association (ACEA) state that there are approximately three million BEVs on EU roads, with around 75,000 public fast chargers available This translates to a ratio of roughly 30 BEVs for every fast charger, and when counting plug-in hybrid EVs this ratio rises to about 52 cars per fast charger. As the number of EVs grows, expanding this network of fast chargers will be vital to meet the evolving demands of EV users.

In response to this challenge, Borgwarner, a global manufacturer of electrification and mobility solutions, has introduced its new DC fast charging system to the commercial EV market. Debuted at IAA Transportation Hanover in September, the charging station is described by chief technology officer Harry Husted as an “excellent solution for rapid charging.” International Transport Manufacturer caught up with Husted during the show to find out more.

SPEED IS KEY

The DC fast charger has a scalable power range of 120kW up to 360kW, making it suitable for fast charging commercial vehicle depots and public and high traffic areas. The conversion from AC to DC voltage happens within the charging station’s power electronics to deliver DC directly to the battery, which substantially reduces charging times.

“The unit is fully integrated in one package,” Husted explains. “It features two charging guns meaning you can charge two vehicles simultaneously, and at 360kW, it’s very high-power. This puts it front and centre of the market for what people are asking for today in terms of fast charging.”

Borgwarner’s DC fast charging stations are specifically designed to handle the high energy demands of commercial and passenger vehicles that often have a need for fast charging ‘on the go’, with its scalable power options able to meet a wide range of depot and charge point operator needs. This means the charger is not only well-suited to the passenger car market but also caters to larger commercial vehicles too.

“We offer the ability to start at 120kW and then you can work your way up to the power level you need,” says Husted. “If customers don’t need the maximum 360kW, they can reduce the price by opting for a lower power level which provides them with greater flexibility.”

THE COMPLETE PACKAGE

“At high power, charging cables can become quite heavy,” Husted continues. “We designed the fast charger with integrated cable management to improve ease of use and counter the cable’s weight, while providing enough cable length to easily reach the charging point on the vehicle. The charger is also one unit, so it is easy to install and has an integrated large full-colour display screen, built-in current monitors and payment interface.”

The charging station is designed to provide a more convenient and streamlined user experience due to quick turnaround time and higher power input. To meet the requirements of different charge point operators, Borgwarner can simply change out the plug on the handle. The charger uses a standard protocol on the backend, making integration into various infrastructures and regions easy.

THE IMPORTANCE OF INFRASTRUCTURE

According to Husted, establishing a reliable, widespread charging infrastructure network is key to supporting viable, long-distance travelling for BEVs. Last year, Borgwarner announced a $20 million investment to accelerate the development, manufacturing and testing of its EV products and charging infrastructure equipment, including battery modules and packs, DC fast charging equipment, and microgrid control and operations, in its Auburn Hills, Dearborn, Hazel Park and Michigan facilities.

“Infrastructure is expensive to install, and sufficient energy supply has to be available in the location that you’re in,” Husted says. “Infrastructure is a really important aspect as we move forwards. You need to have quick and efficient permitting, the right power needs to be available where you are on the map, and getting power distribution to the required site is crucial. There’s also long lead times for some of the electrical components in the system, like switch gear, the big circuit protection and disconnected elements, and transformers. We all want to go fast, but there are some aspects that impact how quickly we can make things happen. However, charging products are becoming more widely available, so we’re going to start seeing installation timing and cost becoming bigger factors.”

Looking ahead, Borgwarner is well placed to continue driving innovation forward in the commercial EV sector, Husted says: “Our approach has been to have a balanced portfolio that we can manage going forwards. We feel good about our role for the foundational part of the business, and on the electrification side. We’re continuing to monitor and move with the market as we go.”