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Heat. Your typical 150kW fast charging is like 3 houses with 200A service all maxed out. Or 25 houses running at typical load. If you want to convert it from 24
by matrix_overload 3y ago
Heat. Your typical 150kW fast charging is like 3 houses with 200A service all maxed out. Or 25 houses running at typical load. If you want to convert it from 240V AC to 340-360V DC (actual voltage goes up as the battery charges), you will need a massive cooling system. For a quick perspective, imagine 1500 laptop chargers working all at once!
Getting it into the vehicle is another thing. 150kW at 360V is about 400A - twice what a modern detached house gets. That needs to get into the vehicle through a relatively flexible cable with a connector. IIRC, that requires an active cooling system (i.e. water loop) inside the cable itself, and the connector will still go through massive temperature swings. So you need materials that can insulate against 400V, bend well, and not crack when you repeatedly heat and cool them several times a day.
Oh, and many chargers [0] don't actually have a 150A or whatever connection to the grid, and instead use internal batteries that load up when nobody is charging, and quickly empty into your car once you pullup to it. That's another cooling loop, extra sensors, and possibly, a heating system, if you want to operate in winter conditions.
[0] https://freewiretech.com/dc-boost-charger/ https://freewiretech.com/dc-boost-charger/