Enabling Fast Electric Vehicle Charging Tutorial

This tutorial explains how rising electrification is driving the need for ultra-fast, scalable EV charging systems that operate at higher power levels while maintaining efficiency and safety. It describes advanced power conversion architectures, including three-phase PFC and isolated DC-DC stages using DAB and LLC topologies, along with integrated power modules and liquid cooling to manage thermal stress. The tutorial concludes by highlighting onsemi’s SiC-based solutions as key enablers for efficient, megawatt-class charging infrastructure built on modular, future-ready designs.

Tutorial Overview

This tutorial provides a comprehensive overview of the technologies and system architectures required to enable ultra-fast, megawatt-scale electric vehicle charging. It explains how rising global electrification and the growth of commercial EVs are driving higher power levels, higher voltages, and stricter efficiency and safety requirements. The tutorial highlights modular, scalable charger designs that can support both light- and heavy-duty vehicles while significantly reducing charging times.

The tutorial further examines the key power conversion stages in high-power chargers, including three-phase power factor correction and isolated DC-DC conversion. It details how advanced topologies such as dual-active bridge (DAB) and resonant LLC converters improve efficiency, reduce EMI, and enable bidirectional operation. The transition to Power Integrated Modules (PIMs) and the use of liquid cooling are presented as critical enablers for managing thermal performance and reliability at megawatt power levels.

Finally, the tutorial presents onsemi’s SiC-based portfolio—including EliteSiC MOSFETs, integrated power modules, and isolated gate drivers—as foundational building blocks for scalable fast-charging systems. Performance data and reference designs demonstrate high efficiency, near-unity power factor, and robust thermal behavior across power levels from tens of kilowatts to megawatts.