Feature: EVs


efficient and reliable operation of electronic systems, Schaffner offers the world’s widest selection of EMC/ EMI filters. Te company’s standard and customer-specific solutions have been developed to help designers of EV charging stations meet international compliance standards whilst improving equipment immunity and safety. Schaffner has designed and produced


EMC filters for many years, which comply with evolving emission limit standards. To suppress conducted interference, these filters are suited to a frequency range of between 150kHz and 30MHz. Tey also prevent other devices in the vicinity from being negatively affected. All standard filters are designed to be


Chokes are the answer One of the most effective ways to tackle EMC/EMI is to fit chokes in their devices since they offer superior levels of performance when it comes to dampening and attenuating noise. A well-designed choke can avoid excessive over-design by mitigating noise to just slightly below the limits set by regulations. Cores must offer maximum flexibility


and deliver optimal efficiencies, achieved through performance/size optimisation. Having access to a large range of performance levels in the chokes they specify represents a significant advantage for designers of EV charging stations, especially in the domestic market. No longer restricted to choosing from a limited range of chokes, designers can be confident that they are fitting a unit that matches precisely the technical demands of a particular EV charging unit. Other requirements of home-based


EV charging stations include the need to protect both sides of the charging process – vehicle side and the grid side. For example, Schaffner’s newly-launched RV Series choke incorporates four windings that are typically installed as three-phase and neutral. For DC applications on the vehicle side the same choke is used, with two windings connected in series


30 March 2024 www.electronicsworld.co.uk


to provide very high attenuation whilst protecting the vehicle from disturbances.


Advanced technology available Complying with the UL/IEC 60938-1/- 2 and UL 1446 E332676 standards, the new choke has been designed for use with power ratings up to 30kW and rated currents from 16A to 50A per phase at 60°C ambient temperature. Te new choke also provides low magnetic leakage flux, excellent winding insulation, low parasitic capacitance and two million hours mean time between failure. It has taken many years for the


electric vehicles market to develop and mature, but, whilst already huge, it will only continue to grow. According to BloombergNEF, global EV sales grew by 83% in 2021 compared with 2020, with major players like Toyota and Volkswagen putting around $170bn into electrification. As governments around the world stipulate that every new vehicle sold aſter 2035 must be fully electric, the shiſt towards e-mobility is inevitable and those serving the industry must be as agile as possible if they are to compete and survive.


Avoiding adverse impacts As a global market leader in electromagnetic solutions that deliver


compatible with IEC60939-3 and other international standards, which makes them suitable for use in any system. For example, the FN2220 series of standard DC filters for EV charging has a current rating of 150-600A, with a capacitance of 990nF. Tis makes the filters ideally suited for use in IEC/EN 61851-1 EV conductive charging systems and UL 2202 EV charging equipment. Schaffner’s FN2220 filter has been


designed to ensure safe charging to 1000VDC, with the smallest version achieving 75kW. A major benefit here is that, because the top end of the scale is marked at 600A and 1000V, fast charging to 600kW can be achieved with just one EMC filter. Because the FN2220 family meets the requirements of both central EV-charging standards, filters do not need to be reviewed for compliance when designing a charging station, and can be integrated instantly, saving time and cutting costs. As well as being EMC requirements


and standards compliant, EV charging stations must provide galvanic separation between input and output sides for their safe operation – typically achieved by medium-frequency transformers. Compared to conventional main-grid transformers, these devices have a much smaller footprint yet deliver the same performance. Tis also makes them suitable for charging stations where space is at a premium.


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