High Efficiency and Smart Transformers for EV Charging Stations

Why do EV charging stations demand “higher standards” for transformers?

Unlike traditional power distribution scenarios, EV charging stations are rapidly developing towards high power, intelligence, and centralization. This means that transformers must not only be “functional,” but also:

• Higher efficiency
• Greater stability
• More intelligent and controllable

I. Challenges of EV Fast Charging Technology for Transformers

1.Power Surge Brought by Ultra-Fast Charging

Current mainstream EV fast charging power has increased from:

60kW → 120kW → 240kW → 350kW

The direct impact on transformers is:

• High instantaneous current
• Significantly increased thermal stress
• Higher requirements for insulation and cooling systems

2.Impact of High-Frequency Power Electronic Devices

EV charging systems extensively use:

• IGBTs
• SiC modules
• High-frequency rectification technology

Transformers need to have:

• Stronger harmonic resistance
• Lower additional losses
• More stable magnetic flux control

II. Core Technologies of High-Efficiency EV Charging Station Transformers

1.Application of Low-Loss Materials

High-permeability silicon steel sheets

Amorphous alloy cores

Optimized lamination structure

These technologies can significantly reduce:

• No-load losses
• Operating electricity costs
• Long-term maintenance pressure

2.Temperature Rise and Cooling System Optimization

Common solutions include:

• Forced air cooling (AF)
• Intelligent temperature control system
• Online monitoring of hotspot temperature

III. Intelligence: A New Direction for EV Charging Station Transformers

1.Online Monitoring and Remote Operation and Maintenance

Through sensors and IoT technology:

• Real-time monitoring of temperature, current, and voltage
• Early warning of abnormal loads and potential faults
• Improving operation and maintenance efficiency and reducing downtime risks

2.Collaboration with Charging Station EMS System

Intelligent transformers can be linked with the charging station energy management system:

• Dynamic load distribution
• Peak shaving and valley filling
• Improving overall power efficiency

IV. Focus Areas for EV Charging Station Transformers in Different Markets

European market: Energy efficiency rating, environmental standards

Middle East market: High-temperature environment adaptability

Africa and Southeast Asia: Stability and cost-effectiveness

North American market: UL/IEEE standard compliance

V. Recommendations for EV Charging Station Transformer Selection

In the early stages of a project, it is recommended to focus on:

• Total power configuration of charging piles
• Future expansion needs
• Grid connection conditions
• Ambient temperature and installation space

EV charging stations are transitioning from “basic infrastructure” to “high-quality operation.” And transformers are an indispensable key equipment in this transformation process. Whoever can lead in efficiency, intelligence, and reliability will gain the upper hand in the global EV infrastructure wave.

Luoyang Datang Energy Technology Co., Ltd. is a high-tech enterprise integrating R&D, manufacturing and supply of power equipment such as transformers, new energy components, distribution cabinets and inverters. With technological innovation as the core, we focus on creating high-reliability and high-performance power solutions to serve global customers. With a strict quality control system and international standard certification, we continue to output excellent products and enable customers to build safe and stable power systems.