Starpower EV Charging Solutions

LiTong Engineering Team

July 25, 2025 • 15 min read

The global electric vehicle market is experiencing unprecedented growth, with charging infrastructure playing a critical role in enabling mass adoption. LiTong Electronics, as an authorized Starpower distributor, provides comprehensive power module solutions that power everything from residential Level 2 chargers to ultra-fast DC charging stations.

EV Charging Infrastructure Overview

The electric vehicle charging ecosystem encompasses a wide range of power levels and applications, each requiring specialized power electronics solutions. Starpower's comprehensive portfolio of IGBT, SiC, and IPM modules enables efficient, reliable charging solutions across the entire spectrum.

Technical Architecture & Design Considerations

Power Stage Architecture

The power stage of an EV charging system is the heart of the charger, responsible for converting AC grid power to the DC power required by the vehicle's battery. The architecture typically includes:

• Power Factor Correction (PFC): Ensures high power quality and compliance with grid standards
• DC-DC Conversion: Steps down high-voltage DC to match battery requirements
• Isolation & Protection: Ensures safety and prevents fault propagation
• Control & Communication: Manages charging protocols and vehicle communication

Key Design Challenges

EV charging systems must address several critical design challenges:

Thermal Management

High-power charging generates significant heat that must be effectively dissipated. Starpower modules feature advanced thermal designs with low thermal resistance and high-temperature operation capabilities.

Power Density

As charging power levels increase, the physical size of charging equipment becomes a critical factor. SiC technology enables significantly higher power density compared to traditional silicon-based solutions.

Efficiency Optimization

Charging efficiency directly impacts operating costs and environmental impact. Wide bandgap semiconductors like SiC offer superior efficiency, especially at high frequencies.

Grid Compatibility

Charging systems must comply with various grid standards and support multiple charging protocols including CCS, CHAdeMO, and Tesla Supercharger standards.

Starpower Module Selection Guide

Performance Optimization Strategies

Efficiency Maximization

Achieving maximum efficiency in EV charging systems requires careful optimization of multiple parameters:

• Switching Frequency Selection: Higher frequencies reduce passive component size but increase switching losses
• Topology Optimization: Selecting the optimal power conversion topology for specific power levels
• Control Algorithm Tuning: Advanced control strategies to minimize losses across operating range
• Thermal Management: Effective heat dissipation to maintain optimal operating temperatures

Reliability Engineering

Reliability is paramount in EV charging infrastructure, where downtime can significantly impact user experience and revenue:

• Component Stress Analysis: Comprehensive analysis of electrical, thermal, and mechanical stresses
• Redundancy Design: Built-in redundancy for critical system components
• Environmental Protection: Robust design for outdoor and harsh environment operation
• Predictive Maintenance: Advanced monitoring and diagnostics for preventive maintenance

Standards Compliance & Certification

EV charging systems must comply with multiple international standards and certifications:

Safety Standards

• UL 2594: Electric vehicle supply equipment safety requirements
• IEC 61851: Electric vehicle conductive charging system requirements
• EN 50110: Operation of electrical installations standards

Performance Standards

• ISO 15118: Vehicle-to-grid communication protocols
• SAE J1772: Electric vehicle and plug-in hybrid electric vehicle conductive charge coupler
• CHAdeMO: DC fast charging protocol standards

Case Studies & Success Stories

Highway Fast Charging Network

A major European EV charging network deployed 200 ultra-fast charging stations using Starpower SiC modules. The implementation achieved:

• 95% efficiency at full power
• 50% reduction in charger footprint
• 30% reduction in total system cost
• 99.9% uptime reliability

Residential Charging Solutions

A North American utility company integrated Starpower IPM modules into their smart home charging program, resulting in:

• 92% overall system efficiency
• Seamless integration with smart grid systems
• Advanced load management capabilities
• Reduced installation complexity by 40%

Future Trends & Innovations

The EV charging landscape is rapidly evolving with several key trends shaping the future:

Wireless Charging

Magnetic resonance technology enabling cable-free charging with Starpower modules providing efficient power transfer at various power levels.

Vehicle-to-Grid (V2G) Integration

Bidirectional charging capabilities allowing EVs to serve as distributed energy storage resources for grid stabilization.

AI-Powered Charging

Machine learning algorithms optimizing charging patterns based on grid conditions, electricity pricing, and user preferences.

Extreme Fast Charging (XFC)

Next-generation charging technology aiming for 500kW+ power levels, requiring advanced thermal management and power density solutions.

Technical Support & Resources

LiTong provides comprehensive technical support for EV charging projects:

Design Support Services

• System Architecture Consulting: Expert guidance on optimal system design
• Simulation Support: Advanced modeling and simulation tools
• Prototype Development: Hands-on support for initial design validation
• Certification Assistance: Guidance through regulatory compliance processes

Training & Education

• EV Charging Technology Workshops: Comprehensive training programs
• Application Engineering Seminars: Deep-dive technical sessions
• Certification Programs: Specialized training for design engineers