Introduction
The objective is to develop power electronics, cooling systems, and grid interface technology that will make today's rapid recharging times possible. Now less science fiction promise, several companies have formed, like Pingalax's R&D division, to prepare these high-powered drainage systems! In the years ahead, we'll see many more efforts in order to build such a system. But they must act with urgency—unlike traditional industries where it is easier for players who are not ready or willing to change what they are doing if a game-changing stage of their competitive development comes along.
From High-Power Systems to the Early DC Fast Charge
The first generation of DC fast chargers only managed between 50 and 150 kW, enough for about 40 minutes to increase a car's charge level from 20% to 80%. But as battery sizes grow larger and fleets of vehicles need quicker turnaround times, these numbers no longer work. Industry began pushing systems upwards for greater capacity around levels between 320 kilowatt-hours in the cases where stations are connected to each other.
Power Electronics: Moving to SiC
To overcome these limitations, Pingalax has moved its high-power chargers from silicon IGBT modules to silicon carbide (SiC) MOSFETs. SiC devices have a faster switching speed than silicon, they can handle higher voltages and generate less heat—which means that, as a practical matter, this translates into units that are smaller and more efficient than their silicon.
Conventional 150 kW silicon chargers converted power at levels of roughly 93–95% in controlled tests. Pingalax’s SiC-based prototypes reached 97–98 percent efficiency, cutting waste and time from half an hour to about 12 minutes for an 80% charge.
Controlling Heat - Liquid Cooling and Real-Time Monitoring
A 1.5-meter cross-section wire carrying several hundred kilowatts of power naturally gets hot. To deal with this, Pingalax engineers have equipped liquid-cooled cables connected to modular cooling apparatus that can be rapidly installed anytime they are necessary. These units also have temperature sensors built in and continuously monitor their thermal conditions, constantly adjusting cooling capacity in real time.
The new approach has cut the rise of temperature by approximately 40% in laboratory testing, compared with conventional air-cooled designs. This not only protects the electronics but also extends the system's lifespan, with fewer failures attributed to thermal stress.
Grid-Connected and With Energy Storage Backing
The emergence of ultra-fast charging also poses questions for the grid. One location can be equivalent to nearly a megawatt of generating power—enough to run many hundreds of homes. So as not to destabilize the supply, Pingalax plans to tie in AI-based load balancing and battery storage modules with its chargers.
In trials, an AI scheduling program was observed to cut peak demand on test grids by about 25%. Coupled with local battery storage, reliance on the national grid can be curbed by a further 30%, making high-power sites more self-sufficient. Preparing for vehicle-to-grid (V2G) operation is also underway. This will see EV owners be able to charge their machines at low demand times and then return energy when it is required (and most costly).
Installation Considerations
It is not just a technical issue installing ultrafast chargers. Comfortably integrated sites have the transmission capacity for a mutualist phenomenon such as 1 MW. Operators face higher funds initially, although they can be recovered through flexible pricing models and government incentives. Pingalax's work shows that while large amounts of up-front funding are necessary, the cost-efficiency is improved as the business grows.
Conclusion
Changing from 150 kW chargers to 800-kW systems is not simply a numerical increase but represents a shift in the main direction of how energy is managed. By pairing SiC power modules with advanced heat management systems and smart grid integration, the Pingalax R&D team has shown that ultra-fast charging is both technologically feasible and commercially available.
With gallium nitride (GaN) semiconductors now under test, engineers are seeking still higher switching speeds. AI-based forecasting models that can identify demand patterns accurately have also begun to emerge.
Most significantly, the focus in terms of integration with renewable energy continues to be on creating charging stations that can operate sustainably as well as fast.
