In the last article, we have already shown you the opportunities of a decentralized charging solution known as Distributed Charging Architecture. This article provides a technical deep dive in the powerblock as one key player in the set-up — what it is, why it is disruptive, and what is EcoG’s role in developing another industry standard.
What is the powerblock and why is it so important? A powerblock is a transformative subsystem that processes a central AC power supply (in case of attached battery storage also a central DC bus is supported), converts it to multiple DC supplies, and distributes the said DC power to different DC dispensers in a flexible manner. It is a sophisticated cabinet housing with various power modules, the beauty of which lies in its modular design, allowing easy insertion and maintenance of components.
One possible functional block illustration of a powerblock can be found below:
The powerblock's versatility extends further with a typical power rating ranging from approximately 0.5 MW to a couple of MWs, accommodating a wide spectrum of charging requirements. Its adaptability is emphasized by the capability to draw input from both low and medium voltage networks, depending on the power rating. Moreover, based on the specific needs of a charging site, the powerblock's modular nature is showcased in its ability to seamlessly integrate multiple units, which can be controlled and monitored centrally or individually.
Two vital components define the prowess of the powerblock: the power modules and the switching matrix. The power modules play a pivotal role in transforming AC to DC, and working in tandem with them is the crucial switching matrix — a dynamic component steering and intelligently allocating power modules to different outlets. This allows for the efficient management of power modules assigned to dispensers based on their real-time vehicle requirements. This strategic design ensures optimal utilization of resources, a factor vital for enhancing overall investment efficiency.
In addition, a standout feature of the powerblock is the deliberate separation of power modules from dispensers. This architectural choice opens avenues for superior cooling concepts, significantly improving cost, volume and energy efficiency at the same time. Similar to unused power module capacity in stand alone chargers, also most of the time the installed cooling capacity per charger as well as the installed max air flow volume per charger is unused. In these points compared to a particular number of stand alone chargers, a power block reduces the number of power modules installed, the cooling capacity installed and the overall volume of the cooling system by using the flexibility of connecting power modules dynamically to dispensers via the switching matrix.
Similar to the trafo substation the power block can be considered as a central and robust grid resource which is handled via remote monitoring likewise in a lifecycle management system. To take the reliability consideration into account, EcoG has set up a powerblock controller series which has its roots in substation control systems and enables close monitoring of the power modules installed, the cooling system and a fail safe operation of the switching matrix.
The resulting advanced control solution elevates the powerblock's performance and positions it as a true innovation of the future in the realm of EV charging infrastructure.
How is EcoG involved in it? Beyond being a hardware solution, EcoG takes a visionary approach by providing a reference design and control for the powerblock — the EcoG Powerblock Starter Kit.
This comprehensive kit provides a reference design for the powerblock and serves as a living implementation for building a series production. The Starter Kit, illustrated above, serves as a rapid prototyping toolbox for manufacturers, allowing them to explore, customize, and accelerate the development of their very own powerblocks with a shortened time2market, low risk at low cost.
Moreover, the EcoG Powerblock Starter Kit offers crucial flexibility in the power module setup, understanding of the intricacies of the switching matrix, therefore unlocking higher utilization possibilities. With the addition of EcoG Universal Core - a universally applicable control system applicable for the powerblock control, seamless communication between powerblocks, dispensers and backends, also a high level of business process integration are further ensured.
The success of powerblock development will not be a solitary achievement. We strongly believe in an ecosystem approach to professionalize and scale EV DC charging development and production. Partnering with industry leaders, EcoG has forged a path of collaboration, accelerating the development of powerblocks with a proven approach already used in the segment of standalone chargers. We already see a strong interest in the US, with two power block product series in preparation and in EU with 4 power block product series started with partners.
In conclusion, EcoG's Powerblock Starter Kit stands as a key innovation in DC fast charging. The modular design, a reliable powerblock controller, and a collaborative market approach make it a formidable solution in shaping the future of electric vehicle charging infrastructure. As we witness the shift towards cleaner transportation, EcoG's Powerblock Starter Kit will no doubt contribute to a more sustainable and efficient charging ecosystem.
Check out more blog posts in this series here: https://get.ecog.io/ecog-distributed-charging-architecture
EcoG is a global IP and tech company working on the rapid expansion of sustainable charging infrastructure for electric vehicles. With its charge controllers, reference designs and software, it enables companies to get products & services to market quickly and scale profitably.
EcoG is already the market leader in Europe with more than 15% market share and a strong footprint in the Indian and North American markets. Overall, EcoG grew four times faster than the market last year. Industrial giants such as Siemens or one of the world’s largest service station equipment suppliers are among its customers. The company continues to grow in 2024 and as a next step invests 14,4M$ in its North American HQ in the USA.