Altran Magnetics

We Design. We Build. We Deliver.

Altran Magnetics will be at The Battery Show Europe in Stuttgart, Germany, from June 18-20, 2024. 

Visit us at Booth 6-A70 to see our latest DC Contactors and discuss how we can support your projects.


DC Contactors and EMI Filters for EV Charging Stations

Executive Summary The electrification of transportation is rapidly advancing, and electric vehicle (EV) charging stations are becoming increasingly ubiquitous. As the demand for EV charging infrastructure grows, so does the need for reliable and efficient components within these systems. Two critical components in EV charging stations are DC contactors and EMI (Electromagnetic Interference) filters. This white paper explores the roles, requirements, and technological considerations for DC contactors and EMI filters in EV charging stations, providing insights into their design, functionality, and impact on overall system performance. Introduction Electric Vehicle (EV) charging stations are essential infrastructure in the transition towards sustainable transportation. These stations must be reliable, efficient, and safe to meet the growing demands of EV users. Central to their operation are DC contactors and EMI filters, which play crucial roles in ensuring the proper functioning of the charging process. Importance of DC Contactors DC contactors are electrically controlled switches that manage high-voltage DC circuits. They are critical in EV charging stations for the following reasons: Safety: Isolate and protect electrical circuits to prevent damage and hazards. Efficiency: Enable efficient power delivery by minimizing losses during switching. Control: Facilitate precise control of power flow within the charging station. Importance of EMI Filters EMI filters are designed to suppress electromagnetic interference, which can disrupt the operation of electronic systems. In EV charging stations, EMI filters are crucial for: Compliance: Ensuring the charging station meets regulatory standards for electromagnetic emissions. Performance: Maintaining the performance and reliability of the charging system by reducing noise and interference. Safety: Protecting sensitive electronic components from electromagnetic disturbances. DC Contactors in EV Charging Stations Function and Design Considerations DC contactors in EV charging stations must handle high voltages and currents reliably. Key considerations in their design include: Voltage and Current Ratings: Contactors must be rated for the maximum voltage and current they will handle. Switching Performance: Efficient and fast switching capabilities to minimize arcing and wear. Thermal Management: Effective dissipation of heat generated during operation to ensure longevity and reliability. Durability: Robust construction to withstand harsh environmental conditions and repeated cycling. Applications in EV Charging Stations Power Connection and Disconnection: DC contactors are used to connect and disconnect the power supply to the EV during the charging process. Protection: They provide overcurrent and short-circuit protection by isolating faulty sections of the circuit. Control Systems: Integral to the control systems that manage the flow of electricity to and from the EV battery. EMI Filters in EV Charging Stations Function and Design Considerations EMI filters mitigate electromagnetic interference to ensure stable operation of the charging station and compliance with regulatory standards. Key design considerations include: Frequency Range: Filters must effectively target the specific frequency ranges where interference is most likely to occur. Insertion Loss: Minimizing the loss of signal strength when the filter is inserted into the circuit. Size and Form Factor: Compact designs that fit within the spatial constraints of the charging station. Temperature Stability: Maintaining performance across a wide range of operating temperatures. Applications in EV Charging Stations Noise Reduction: EMI filters reduce Electro-Magnetic noise generated by the switching components and power electronics in the charging station. Compliance: Ensure the charging station meets international standards for electromagnetic emissions (e.g., FCC, CE). Protection: Safeguard sensitive electronic components from interference that could cause malfunction or damage. A suitable EMI filter is required on the input power side of EV chargers.  This is normally Grid/AC voltage, but it can also be combined with power fed from sources like Solar Panels or Battery Storage Systems.  These filters are used to protect the source of power.  A DC EMI filter is necessary to protect the car battery and associate electronic circuitry.  Below diagram show the position of EMI filters in EV charging stations.    Integration and System Considerations Compatibility and Interoperability Ensuring compatibility and interoperability of DC contactors and EMI filters with other components in the charging station is essential for seamless operation. This involves: Standardization: Adhering to industry standards for electrical characteristics and mechanical interfaces. Testing and Validation: Rigorous testing to validate the performance and reliability of the components under various operating conditions. Modularity: Designing components that can be easily replaced or upgraded to accommodate future advancements in technology. Challenges and Solutions Heat Management: Implementing advanced cooling techniques, such as liquid cooling or heat sinks, to manage the heat generated by high-power components. Miniaturization: Developing compact designs without compromising performance, to fit within the limited space of charging stations. Cost Efficiency: Balancing cost with performance to ensure the charging station is economically viable. Conclusion DC contactors and EMI filters are vital components in the reliable and efficient operation of EV charging stations. As the demand for EV infrastructure continues to grow, advancements in these technologies will be critical to meeting the needs of modern transportation. By addressing the challenges of heat management, miniaturization, and cost efficiency, and ensuring compatibility and compliance, manufacturers can develop robust solutions that support the widespread adoption of electric vehicles. References IEC 61851-1:2017 – Electric vehicle conductive charging system – Part 1: General requirements. SAE J1772 – SAE Electric Vehicle and Plug-in Hybrid Electric Vehicle Conductive Charge Coupler. “Electromagnetic Interference (EMI) Issues in Electric Vehicle (EV) Charging Infrastructure,” IEEE Transactions on Power Electronics. “Design and Implementation of High-Performance DC Contactors for Electric Vehicle Charging Stations,” Journal of Electrical Engineering and Technology. By exploring and addressing the complexities associated with DC contactors and EMI filters, this white paper aims to contribute to the development of more reliable, efficient, and safe EV charging stations, ultimately supporting the transition to a more sustainable transportation future. Download

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AEV250: Enhancing Material Handling with High Voltage DC Contactors

The Altran Magnetics’ AEV250 is an advanced high voltage DC (HVDC) contactor designed to protect energy storagesystems. As the material handling industry transitions from lead-acid to lithium battery packs, the Altran Magneticsproduct range provides critical functionalities that ensure safety, efficiency, and longevity of these new battery systems.This whitepaper outlines the key benefits, and application scenarios of the AEV250, highlighting its 1000V 500Acapability and its role in modernizing material handling operations. The material handling industry is undergoing a significant transformation with the shift from lead-acid to lithium batterypacks. This change is driven by the need for more efficient, reliable, and environmentally friendly energy storagesolutions. The Altran Magnetics’ AEV250 is engineered to address the challenges associated with high voltage DCapplications in material handling equipment, providing a robust and reliable solution for lithium battery systems. Protection The AEV250 offers critical protection for high voltage DC circuits in lithium battery systems, using inert gas technologyand arc blowout magnets to maintain low contact resistance and prevent faults, ensuring component longevity. Efficiency By minimizing contact resistance and using an internal coil economizer, the AEV250 reduces energy losses and powerconsumption, enhancing system efficiency and offering environmental and cost benefits. Reliability Constructed with high-quality materials and advanced techniques, the AEV250 withstands harsh environments,maintaining operation in demanding conditions. Its robust design is supported by comprehensive testing and fulltraceability via QR codes. Application Scenarios • Forklifts and Industrial Trucks• Automated Guided Vehicles (AGVs)• Renewable Energy Integration• Off-Grid and Remote Operations Conclusion The AEV250 is a key driver in modernizing the material handling industry with lithium battery packs. Its versatileapplication across various devices underscores its pivotal role in transitioning to more sustainable and efficient energysolutions. Discover the benefits of the AEV250 for your operations by contacting our technical sales team or visiting ourwebsite. Download

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Unveiling the Ceramic Advantage with the AEVF400 Series

In a competitive market, staying ahead means having both experience and quality on your side. At Altran Magnetics, we bring over twenty years of expertise to the table, specializing in ceramic gas-filled contactors – a field where precision is key. Our commitment to excellence is evident in our eleven automated manufacturing lines, producing over six million contactors annually. With twenty-five series ranging from 20A to 1000A, we cover a wide range of needs. What sets us apart is our rigorous quality control. Each component is thoroughly tested and traceable through a unique QR code, ensuring reliability every step of the way. Introducing the AEVF400 Series High Voltage DC Contactor – a true embodiment of our ethos of innovation and reliability. Designed to meet the ever-evolving needs of modern industries, from electric vehicles and charging infrastructure to renewable energy systems, the AEVF400 Series sets a new benchmark for high-voltage switching applications. At the heart of the AEVF400 Series lies cutting-edge technology that delivers unparalleled reliability, safety, and performance. Despite its compact footprint, comparable to that of a traditional 250A product, the AEVF400 boasts the capabilities of a 400A powerhouse. This remarkable feat of engineering ensures seamless high-current carry and voltage switching, making it the preferred choice for discerning professionals across industries. With its ability to handle up to 1000V bi-directional switching, the AEVF400 Series redefines market standards, setting new benchmarks for performance and quality. Each unit is crafted with precision and rigorously tested to meet our stringent quality standards, ensuring that our customers receive nothing but the best. In an era where innovation is the key to success, the AEVF400 Series stands tall as a testament to our commitment to excellence. Backed by over two decades of expertise in ceramic gas-filled contactors, Altran Magnetics continues to lead the charge towards a future powered by reliable, efficient, and sustainable technologies. Join us on this journey as we redefine the possibilities of high-voltage switching, one AEVF400 Series contactor at a time.  Download

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DC Contactors, Fit and Forget?

Ten years ago, knowing how your DC contactors were being used was as detailed as designing it in and seeing how it performs. Was that enough? Absolutely not, over the past decade, the way contactors are being used has changed, the systems have changed and how we monitor these components has also changed. Gone are the times of fitting a component in a system and forgetting about it. It’s important to understand how these components are being used. With many EV applications or fast charger applications, our customers always monitor the current flowing through our contactors, the temperatures the product has been subjected to and how many times the product has had to “hot switch”. What’s even more important is learning what loads that were being switched when theevent happened. We want to know as much as possible about the day-to-day life of the contactor, if there is an unusual event causing excess temperatures, we’d like to know why, and understand how that effects the longevity of the contactor.  Knowledge is power when it comes to DC contactor usage, the data allows our customers to apply preventative measures when it comes to maintenance, the alternative is reactive maintenance, which comes at considerable cost. Replacing a failed component on a fast charger comes at a considerable cost in labour and in monetary terms, for that reason, using the data available, by utilising sensors in their designs, the manufacturers can estimate the life of components, applypreventative maintenance measures, and ensure there is zero down time for their products, this gives the end user a seamless experience. To understand in further detail, how to monitor and gauge the life expectancy of DC switching products, you can talk to us, Altran Magnetics, the experts in DC switching technology. Download

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