An Optimal Multi-Zone Fast-Charging System Architecture for MW-Scale EV Charging Sites

Abstract

In this paper, a detailed review of electric vehicle (EV) charging station architectures is first presented, and then an optimal architecture suitable for a large MW-scale EV fast-charging station (EVFS) with multiple fast chargers is proposed and evaluated. The study examines various EVFS architectures, including those currently deployed in commercial sites. Most EVFS implementations use either a common AC-bus or a common DC-bus configuration, with DC-bus architectures being slightly more predominant. The paper analyzes the EV charging and battery energy storage system (BESS) requirements for future large-scale EVFSs and identifies key implementation challenges associated with the full adoption of the common DC-bus approach. To overcome these limitations, a novel multi-zone EVFS architecture is proposed that employs an optimal combination of isolated and non-isolated DC-DC converter topologies while maintaining galvanic isolation for EVs. The system efficiency and total power converter capacity requirements of the proposed architecture are evaluated and compared with those of other EVFS models. A major feature of the proposed design is its multi-zone division and zonal isolation capabilities, which are not present in conventional EVFS architectures. These advantages are demonstrated through a scaled-up model consisting of 156 EV fast chargers. The analysis highlights the superior performance of the proposed multi-zone EVFS architecture in terms of efficiency, total power converter requirements, fault tolerance, and reduced grid impacts, making it the best solution for reliable and scalable MW-scale commercial EVFS systems of the future.