Power application control units / Battery charging units

Conductive charging

Here the battery charging unit converts power from the mains into a form which can be used by the battery of the electric vehicle. KOSTAL is already developing and manufacturing battery charging units designed for the automobile, taking account of factors such as cost, space, weight, robustness, power density and efficiency, based on a modular component platform for various power classes.

Vehicle integration

Lack of space and limits on weight, together with the power density required, mean that conventionally cooled systems are not the answer. Liquid-cooled systems offer significant advantages in regard to these factors but they must be connected to the vehicle’s own cooling system. The KOSTAL battery charging unit ensures the complete separation of electrical and cooling systems, while maintaining good thermal links for electrical components.

Safety

There are stringent safety requirements in the automotive industry regarding safety in connection with high voltages (protection of persons against electric shocks) and these are met by a battery charging unit with galvanic separation – i.e., separating the mains power supply from the vehicle.

In addition, reinforced insulation is fitted, to prevent any potential risk if there is a DC problem.

System integration

In addition to normal AC charging, rapid DC charging is also supported in accordance with the DC rapid charging standard CHAdeMO. To cover this charging procedure and other functions the KOSTAL battery charging unit provides control of external, peripheral services (DC high-voltage contactor, lighting, locking function, etc.) as well as communication via Power-Line or a CAN interface. Further potential exists in the integration of complete charging management.