Evolving toward enhanced EV charging

As the demand for electric vehicles (EVs) and enhanced EV charging options increases, engineers face design challenges to deploy more charging stations. This article explores key challenges, such as faster charging, battery enhancements, and thermal management, and discusses the role of advanced connectivity solutions and technological advances in supporting the transition towards more efficient and reliable EV charging.

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A growing global emphasis on transformational energy is converging with consumer expectations in the transportation space involving safety, comfort, convenience and functionality — spurring a revolution in automotive architecture and a shift toward electric vehicles (EVs). With EVs expected to become increasingly prevalent on our roadways, there’s also a rising call for broader implementation of both commercial and residential EV charging stations designed to help expedite battery replenishment.

As a result, engineers everywhere are grappling with complex design dynamics as they consider ways to deploy more EV charging stations along streets, on highways, in homes and at workplaces. Since EVs are still an emerging market, brand reputations are riding on these critical decisions. In this environment of intensified awareness, an expanded EV charging infrastructure needs to address important factors like safety, usability, reliability, thermal management and evolving regulatory standards. Read on for timely insights regarding EV charging-related challenges and opportunities.

Key design challenges

As regions around the world explore EVs, designs are advancing and the market is slated to gain speed. In fact, according to UBS Investment Bank, EVs are predicted to account for 20% of new car sales worldwide by 2025 and 50% by 2030. Similarly, JP Morgan notes that hybrid gas-electric vehicles will represent nearly a quarter of automotive sales worldwide by 2025. Yet several key challenges are still being addressed to help EV charging innovations follow suit. These include:

A changing charging landscape

As the need for enhanced EV charging accessibility and efficiency becomes more imperative, additional technological and infrastructural advances are also lending comprehensive support. Some examples are summarized below.

48V Power

While the 12V power model has been an automotive industry standard since the 1950s, changing emissions laws are combining with the dynamics noted above to drive a shift toward 48V design. In fact, vehicles known as mild hybrids are already incorporating 48V systems to sustain functions like regenerative braking. Unlike full hybrids, mild hybrids don’t require a charge. They use both a gas engine and small electric battery, and can store recovered brake energy for future use.

48V power supports smaller component production for every type of EV, allowing automotive designers to pack more features into a given space. That means vehicles can include more enhanced wireless charging, infotainment and advanced driver assistance system (ADAS) capabilities. Because smaller components require fewer materials, production costs and total energy use can likewise decrease.

More efficient 48V systems also help control emissions, while creating lighter vehicles with less drag — so those vehicles can handle better and travel farther on a single tank or charge. Another key benefit is that 48V systems can accommodate higher voltage that helps improve power distribution while reducing battery load. In terms of EV charging, this can mean:

Achieving the promise of 48V for full hybrids and EVs, however, calls for energy control systems that can manage higher voltage levels to optimize charging efficiency — along with connectors that help simplify architectural upgrades.

Connectivity Innovations

That’s why innovations like Molex MX150 mid-voltage connectors create important advantages. Based on the field-tested Molex MX150 design, these single- and dual-row solutions support upgrades to 48V wiring architecture while minimizing additional design engineering work.

This is just one example of how leading-edge connector engineering is paving the way for a more efficient EV future. Because today’s automotive interconnect solutions power vehicles and chargers, they need to pull quadruple duty: supporting efficient upgrades, accommodating space constraints, mitigating heat generation and withstanding harsh conditions for safe, reliable performance.

EVs themselves need sealed, miniaturized and ruggedized interconnects with higher pitches and more integrated functionality. Advanced EV chargers demand an array of dependable and carefully integrated wire-to-board connectors, board-to-board connectors, terminal blocks, barrier strips, memory card connectors and more — all of which need to operate seamlessly and predictably when battery levels are low. When drivers plug in, it’s equally imperative to avoid putting the vehicle, its occupants or surrounding structures at risk.

These high stakes require proven engineering expertise combined with market insight, multi-disciplinary perspectives and integrated manufacturing capabilities. For instance, Molex regularly works alongside Tier 1 automakers and trusted industry suppliers to diversify customer offerings in ways that are safe, compliant and commercially viable. Molex also uses digital twin technology to proactively optimize the performance of their connectivity product portfolios. Powered by historical data, machine learning (ML) algorithms and the latest AI advances, digital twin technology gives both designers and operators early real-world insights to help boost performance.

As widespread awareness of transformational energy options combines with escalating consumer demand for enhanced vehicle safety, comfort, convenience and infotainment, EVs and enhanced EV charging options are assuming center stage. Across this multifaceted industry landscape, Molex collaborates with Arrow Electronics to offer advanced interconnect solutions for a variety of EV-related applications. Molex's innovations — which include wire-to-wire, board-to-board and wire-to-board connectors, as well as cable assemblies and sensors — reflect decades of proven automotive expertise to deliver leading-edge performance that keeps ever-evolving customer innovations ahead of the curve.