Fast charging circuit protection technology – Tech News 2304

Apr 9, 2023 | Tech News


Fast charging circuit protection technology

For you to analyze the fast charging circuit protection technology market and principle. This is also the base of the EV charging industry.

Fast charging circuit protection technology

Market Values

According to forecasts, the value of the global circuit protection market is expected to increase from $44.5 billion in 2021 to $80.82 billion in 2030, with a compound annual growth rate of 5.9% during this period. The continuous growth of the automotive industry and widespread use of consumer electronic products are among the key factors driving market expansion. With the ongoing rise of autonomous vehicles, electric cars, and hybrid vehicles, modern automobiles are equipped with cutting-edge electronic devices, leading to a sharp increase in demand for circuit protection in the automotive sector.

Technical Analysis

DC fast charging is currently the fastest method for charging electric vehicles, but it is also the most expensive. Electric vehicles are connected to the power grid through an AC to DC power conversion module, which provides a range of direct current voltage from 120VDC to 920VDC, with potential for even higher voltages in the future.

It is evident that design engineers will inevitably face multiple challenges in developing charging stations, with safety being the foremost concern. This is because users must connect their vehicles to charging stations that have a power capacity exceeding 300kW. Other important design parameters include reducing power consumption, maintaining high efficiency even under maximum temperature rise, and ensuring reliable operation of outdoor charging stations.

Fire prevention

Fire is the primary hazard associated with the installation of power supply equipment for electric vehicles. While fires can be caused by various factors, the most common cause is the aging of wires and power sources within buildings or structures where charging stations are installed. Whether it’s an AC1 or AC2 charging station, all electrical connections should meet the charging requirements of electric vehicle power supply equipment and be compatible with the technical specifications of each device. The main focus for surge protection devices (SPDs) required here is at the main distribution panel.

Surge protection

The current generated in AC networks can reach up to 12.5kA per phase, according to IEC61643-11. The SPD at the input of the main distribution panel must be able to withstand external transient current impulses caused by lightning and other factors. Additionally, they must be free from leakage current and insensitive to short-term voltage peaks that may occur due to low-voltage network faults. These measures effectively ensure a long equipment lifespan and high reliability of SPDs.


Another potential danger involving electric vehicle power supply equipment is the failure of Ground Fault Circuit Interrupters (GFCIs). Standard electric vehicle charging stations are connected to their power source through GFCI outlets, effectively preventing electrical shocks. However, reports have shown that in some parts of the world, the failure rate of GFCI breakers reaches 57%, with lightning, aging, and wear being the main causes of these equipment failures. Therefore, before installing electric vehicle power supply equipment, it is essential to thoroughly inspect the connected GFCI to ensure there is no damage present.

Overheating protection

The use of DC fast chargers can shorten the charging time of electric vehicle batteries. These chargers have a rated power of up to 350kW and can deliver a charging current of 400A. However, their practical usage presents a significant technological challenge in terms of overheating caused by the high power and current required for charging. Therefore, it is necessary to properly monitor the temperature of the charging stations, connector systems, busbars, power electronic devices, and high-voltage batteries to ensure the safety and effectiveness of the charging process. Inadequate temperature monitoring can result in component wear, shortened lifespan or even failures. In extreme cases, severe overheating may lead to battery fires.

Circuit breaker

For DC charging stations, a fast-acting high-current fuse is also required at the connection point with the AC power source in order to prevent overload currents and short circuits. This fuse must have an adequately high current interrupt rating to ensure its reliable operation.


The charging equipment and the vehicles it connects to both have sensitive electronic components that need protection from factors such as overvoltage, overcurrent, high temperature rise, lightning surges, and other impacts. With the increasing popularity of electric vehicles and the promotion of new “fast charging” technology, there is a growing demand for reliable and safe charging infrastructure. This trend will undoubtedly benefit the circuit protection market.

In 2022, the global circuit protection market reached a size of $42.8 billion. Looking ahead, IMARC Group predicts that by 2027, the market in this field will reach $57.9 billion with a compound annual growth rate (CAGR) of 5.6% from 2022 to 2027.The contribution made by the electric vehicle market in this projection cannot be underestimated.



Submit a Comment

Your email address will not be published. Required fields are marked *