Innovating electrical infrastructure for high-current EV fast charging

Background

2020 saw the launch of Porsche’s all-electric supercar in the UK. The vehicle was designed with the ability to accept a high-input DC fast charge. This is the first of its type in the UK. Prior to launch, the client needed a solution for alternative charging modes that could be used as a template for future dealership installations across the country.

The Brief

The design installations needed to be developed as a standard template that could be implemented in various different sites across the UK. All versions of the design had to accommodate a maximum charging rate of 320kW to each vehicle.

Challenges

The challenges we had to overcome include:

• The original client design, developed in Germany, is based on different regulations and standards to the UK. We, therefore, had to analyse and translate the design to be suitable for our use in the UK.
• A new cable type was used which is not currently registered for sale in the UK. We had to undertake our calculations, to be verified by the manufacturer.
• With a heavy load plant, many hours were spent engineering the cabling so that it would be physically accepted by the plant and be practical to install.
• Determining the earthing strategy for the installations given the high DC current.

Process

By using software, we were able to model the different outline designs to determine the performance of the installations and comply with UK regulations.

Outcome

Using our experience in electrical design, and our solid grounding in EV installations, we were able to deliver three compliant designs to the client that could be developed for installation at any site across the UK.