MV Power Systems
Featured
2023
350kW DC Fast Charger
Complete mechanical and electrical design of a 350kW DC fast charging station for electric vehicles.
Role
Senior Design Engineer
Client
EV Infrastructure Company
Duration
14 months
Year
2023
Technologies
Vienna RectifierLLC ConverterCCS/CHAdeMOSolidWorksSheet Metal DesignDFMISO 15118
Key Highlights
- ✓350kW peak charging power
- ✓94% overall efficiency
- ✓15-minute charge to 80% (typical EV)
- ✓V2G ready architecture
- ✓Modular power stack design
This project encompassed the full development cycle of a 350kW DC fast charging station, from initial concept through to production-ready design. The charger supports both CCS and CHAdeMO standards with liquid-cooled cables.
System Architecture
Power Conversion
- Three-phase Vienna rectifier front-end
- Interleaved LLC resonant converter
- Wide output voltage range: 200-1000V DC
Mechanical Design
- IP54-rated outdoor enclosure
- Forced air cooling with redundant fans
- Cable management system
- User interface with 15" touchscreen
Safety and Compliance
The design meets all relevant standards including:
- IEC 61851-23 (DC charging)
- UL 2202 (EV charging equipment)
- ISO 15118 (V2G communication)
Production Engineering
Design for manufacturing (DFM) principles were applied throughout, resulting in a modular architecture that simplifies assembly and enables field serviceability.