Introduction
Electric vehicle sales aren’t just reshaping the automotive grid; they are also dismantling much of the apparatus that powers it. Charging systems that were formerly based on low power levels currently have to fulfill several hundred kilowatts. Efficiency, stability, and durability are particularly important. And at the heart of that transformation are power semiconductors, the devices that convert and control electricity inside a charger. Semiconductors have become the priority research direction of Pingalax. By going beyond the silicon standard and designing modules with wide-bandgap material such as silicon carbide (SiC), the company has been able to increase both the conversion efficiency and reduce the heat losses in its charging systems.From Silicon to Wide-Bandgap Devices
For decades, transistors based on silicon were the workhorses of power electronics. They pulled through in the early days of EV charging at low power levels. But with chargers rising above 150 kW, silicon started to hit the wall: Switching losses became higher, cooling became more bulky, and efficiency gains evaporated.
SiC MOSFETs, and in some cases GaN FETs, have changed the calculus. These parts work at a higher frequency and voltage and consume less power. Practically, that amounts to smaller chargers, faster response times, and less wasted energy. For ultra-fast charging – 800 V and 1000 V architectures – SiC is now the incumbent solution.
Pingalax’s Approach
In its recent product generation, Pingalax uses different semiconductor technologies depending on the power range:
- AC chargers (7–22 kW) employ fast MOSFETs with conversion efficiencies of nearly 99%.
- Mid-power level DC chargers (20–40 kW) apply SiC together with IGBT modules to achieve the trade-off between cost and performance.
- Fast DC chargers (60–240 kW) are constituted mainly by SiC MOSFETs, with an efficiency of about 96–99%.
- Ultra high-speed (320–800 kW) systems are available using advanced full SiC modules with GaN transistors in some models and achieve laboratory-tested efficiencies up to 99.5%.
This blend means the firm can tailor technology to application, whether that’s a small unit in a hotel car park or a powerful installation on a motorway corridor.
Reliability Through Thermal Management
High power equals heat: End up discussing heat a lot. To prolong the life of its components, Pingalax has been investing in cooling research. For systems larger than 320 kW, liquid cooling systems are applied, whereas mid-range power ratings are based on optimized air-cooled modules. Power devices feature thermally conductive coatings that mitigate local stress as well.
SiC chargers tested in the company’s labs released 50% less heat compared to silicon chargers – thanks to the higher efficiency of this technology. Lifespans in excess of 100,000 charge cycles are predicted on simulation with reduced maintenance requirements.
Testing and Validation
Here is a series of in-house module tests that modules go through before being released:
- Efficiency comparison between IGBT and SiC concepts.
- Temperature cycling -40°C to 75°C.
- Heavy-load tests to represent simultaneous charging of several electric vehicles.
The information from these tests is then compared against international benchmarks. Pingalax chargers have passed ISO 9001, IATF 16949, CE, and UN38.3 that maintain performance and adherence.
Looking Ahead
Semiconductor progression in EV charging is accelerating. Pingalax’s R&D department is currently looking into:
- Unit miniaturization of power electronics.
- AI-enabled scheduling algorithms that decide on the power allocation in real-time.
- Youngish forms of GaN devices for high power density.
Conclusion
Power semiconductors are transforming the EV charging industry without anyone noticing. What was once an Achilles’ heel — the conversion losses and heat — has turned into a land of rapid progress. Wide-bandgap technology, paired with improved cooling and smart control, is revolutionizing charging sessions, making them quicker, more efficient, and safer.
For Pingalax, this isn’t just about semiconductors as components. It’s about establishing the technology infrastructure that will enable EV infrastructure to develop sustainably over the next 10 years.
