Battery Swapping Station: Optional Power Supply Solutions for EV Charging

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The demand and market size of battery swapping stations is currently growing as the demand for electric vehicles (EVs) increases. However, the limitations of insufficient battery capacity have become a concern for the long-distance driving range, especially for two-wheeled EVs. Battery swapping stations provide a power supply solution by refueling electric vehicles in a fast way, replacing traditional charging sessions by swapping empty batteries for fully charged ones, not only preventing waiting anxiety but also quickly solving mileage anxiety, thereby eliminating the need for long charging times and allowing for uninterrupted travel.

Without a doubt, this innovation has the potential to significantly improve the practicality and usability of EVs, particularly for those who frequently travel long distances.

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Why will Battery Swapping Stations Boost?

One of the most important reasons why there will be an increase in the number of battery-swapping stations is that many automobile firms are also expanding their operations and attempting to break into the international markets for electric cars. To illustrate, let’s go through the experience and efforts that a company dedicated to e-mobility to break into the market for electric vehicles in Norway.

A Chinese manufacturer of electric vehicles made its debut in foreign markets in Norway. Apart from the sale of automobiles, the firm plans to introduce its battery swapping stations, specialized service centers, and car charging stations into the Norwegian market.

When it comes to charging, the firm has been a pioneer since they have included a battery-swap solution in addition to the more standard plug and charge stations.

Benefits of the Battery-Swapping Charging Mode

The following are the three most significant benefits of the battery-swapping charging mode:

1. Timesaving

Compared to the charging mode of the charging station, it offers a timesaving option. To be more concise, the battery-swapping process takes just a few minutes to complete, allowing drivers to continue their journey without waiting for hours for a full charge.

2. Safe

The EVs are often overcharged and discharged during use, which can cause damage to the power battery and lead to the degradation of the battery capacity. The battery swapping station will provide centralized professional charging and discharging management for the batteries, which is much safer than the charging station method that the drivers do individually.

3. Relieve the Grid Network Stress

Last but not least, the battery-swapping mode can also effectively relieve the grid load. For traditional charging methods, a large number of electric vehicles charging at the same time will pose a huge threat to the grid network; while the battery swapping station can choose to supplement the power during the low period of grid load, effectively reducing the stress brought by centralized charging to the grid.

How to Choose an Optimal and Practical Power Supply Solution?

Choosing the right power supply solution for battery swapping stations is fundamental for ensuring the efficient and safe operation of the station. When making this choice, there are three significant elements to consider: reliability, performance, and delivery.

  • Reliability: The power supply solution must be reliable and withstand harsh operating conditions, such as temperature fluctuations, power surges, and voltage spikes. The power supply system of the battery swapping station consists of a three-phase power input, which is boosted to 800+VDC to meet the 800VDC battery platform through a Boost circuit. Considering the fluctuation of the rectification voltage of the boost circuit, the input range of the auxiliary power supply is required to reach 1500V.
  • Performance: The power supply solution should deliver a wide range of input voltage, a wide operating temperature range such as -40℃ to +70℃, high isolation voltage, high level of safety coupled with high efficiency, low ripple and noise. At the same time, the power solution should have multiple protections, such as input under-voltage protection, input reverse polarity protection, output short circuit, over- current, and over-voltage protection, to prevent voltage and current failure and provide timely protection accordingly.
  • Delivery: The power supply solution must be readily available and have a short lead time for delivery. It is crucial for a reliable supplier to Mornsun Power 4 / 7 Page have a proven track record for delivering high-quality and reliable power supplies on time. MORNSUN has a complete product line layout, a mature R&D platform, a safe and reliable material supply platform, and a production line with an automatic rate of up to 70%, significantly enabling customers’ requirements for fast delivery and helping them to shorten their time to the market.  

Finding the Most Efficient and Stable Power Supply Solution!

The power supply system of a battery swapping station typically consists of a boost circuit, control circuit, charging circuit, power battery, and BMS unit. The charging circuit is used to charge the replacement batteries to a safe and suitable level. The battery management system ensures that the batteries are charged and discharged safely, while the control system manages the entire process of battery swapping. These systems work together to provide an efficient and convenient battery replacement solution for swapping stations.

At the same time, MORNSUN’s products work together to form a comprehensive power supply solution by providing efficient and stable power conversion and monitoring, including:

  • The DC/DC converters with an ultra-wide input voltage of 200- 1500VDC, such as the PV15-29B24R3 and PV40-29B15, provide power supply for the control board and drive the IGBT and SiC (isolated 3000VDC), which are suitable for the outdoor environment.
  • The current sensor TL100-D2C, with an accuracy of up to 0.3% and linearity of up to 0.05%, provides accurate monitoring of the current flow in the system, allowing for real-time monitoring and protection against failures.
  • The onboard AC/DC converter module LH60 series power up BMS and the main control board. With potting package and excellent heat dissipation performance, it can help the customer eliminate complex wire wiring and enhance the safety of the system. 

Why MORNSUN

Established in 1998, MORNSUN has become a leading provider of PSU power supply solutions in a wide range of industries. MORNSUN services the worldwide market through its 25 years of expertise in power supply design and PSU production.

In order to provide more professional and applicable power products to the EV charging industry, MORNSUN not only has one-stop power supply solutions for traditional AC and DC piles but also plans ahead for new market demands and expansion areas of the charging station industry, such as battery swapping stations, optical storage, and charging, etc. Backed by high-quality products, cutting-edge technology, and prompt and friendly service at every level, it keeps developing special power supplies corresponding to the needs of the industry and helping customers succeed in their business.

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