Charging technology and chargers

Gentle, effective and energy-efficient

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The right charging technology plays a decisive role in maximizing the service life of battery packs and optimizing energy consumption.
Incap Germany has extensive experience in this field and offers you gentle and effective charging processes for battery packs with voltages from 12 to 1000 VDC.

Advantages and strengths

the charging technology

Flexibility and adaptability

Application-specific charging functions can be created by configuring various current and voltage parameters. This allows precise control of the charging process and enables an optimum balance between charging and service life of the cells.

Comprehensive diagnostic capability

CAN, Modbus, I2C or Ethernet interfaces are available as standard, making it possible to use various measurement and control parameters for control and diagnostics. This ensures optimum charging of the battery and enables precise monitoring of the charging process in real time.

Voltage measurement using external sensors

By measuring the voltage directly at the battery terminals, the current-dependent voltage loss can be compensated for via the ohmic resistance of the cables. This shortens the charging time and optimizes the performance of the battery pack.

Measuring the impedance of connected peripherals

This enables the early detection of incorrectly plugged connections or defective cables as well as possible cell damage. By identifying these interference factors, safe and reliable charging can be guaranteed.

Areas of application for our charging technology

Various application areas with different requirements

Onboard charging technology in battery electric vehicles

Requirements

Voltage range and performance
Charging efficiency
Communication interfaces
Safety and security
Compact design and heat dissipation
Robustness and reliability

These technical requirements are crucial to ensure efficient and safe onboard charging technology for battery electric vehicles and to achieve optimum charger performance.

Voltage range and performance

Chargers for onboard applications must be able to cover the required voltage range, which can vary greatly depending on the vehicle type and battery configuration. Typically, the voltage for vehicle batteries is in the range of 200 to 800 VDC.

Charging efficiency

Efficiency is also a decisive factor in onboard charging technology, as high efficiency reduces charging time and minimizes energy consumption. Chargers should therefore be highly efficient in order to minimize losses during the charging process.

Communication interfaces

Chargers for onboard applications must be able to interact with the vehicle communication system. This enables the exchange of information such as battery status, charging current, state of charge, etc. Common interfaces such as CAN (Controller Area Network) or Ethernet are used to enable communication between the charger and the vehicle.

Security

Chargers for electric vehicles must meet very high safety standards in order to minimize potential risks. This includes protective devices against overcurrent, overvoltage, short circuits and overheating. Furthermore, insulation mechanisms are of great importance for maximum electrical safety.

Compact design and heat dissipation

Space is limited in a vehicle, so a compact and space-saving design is important for onboard chargers. In addition, chargers must have effective heat dissipation systems to ensure reliable temperature management and prevent overheating.

Robustness and reliability

Onboard chargers must be able to withstand the harsh conditions in the vehicle environment, including vibrations, temperature fluctuations and humidity. They must therefore be designed to be robust and reliable to ensure continued performance and operational safety.

Charging technology for industrial UPS systems

Requirements

Charging function according to the cell chemistry
Charging power according to the battery capacity
Battery monitoring and diagnostic functions
Overvoltage and overcurrent protection
Modularity and scalability

The above technical requirements are crucial to ensure the performance, reliability and longevity of industrial UPS systems. By meeting these requirements, UPS systems can operate efficiently and reliably to protect critical applications and data centers from power outages and voltage fluctuations.

Charging power according to battery capacity

Industrial UPS systems generally use larger battery banks with high capacity to ensure sufficient power supply during mains failures. Chargers must therefore be able to charge these large battery banks to their maximum capacity. A high charging capacity is required to minimize charging times and maximize the availability of the UPS system.

Battery monitoring and diagnostic functions

Chargers for industrial UPS systems should offer advanced monitoring and diagnostic functions. These include measuring battery parameters such as voltage, current and temperature as well as monitoring the state of charge and battery life. These functions enable precise monitoring of the battery condition and early detection of malfunctions or wear to enable timely maintenance or replacement of the batteries.

Charging function according to the cell chemistry

Industrial UPS systems require gentle charging technology in order to maximize the service life of the batteries and maintain their performance. Chargers should therefore have intelligent charging algorithms that optimize the charging curves and parameters according to the specific requirements of the battery technology.

Overvoltage and overcurrent protection

The chemical properties of batteries pose a potential safety risk. For this reason, various safety precautions within the battery, but also on peripheral components such as chargers, are essential.

Modularity and scalability

Industrial UPS systems usually require maximum availability. Chargers for such systems must be able to support redundant configurations and parallel operation to ensure uninterrupted operation, even in the event of a charging module failure.

Charging technology for mobile electrical applications

Requirements

Compatibility with different battery types
Flexible charging power and voltage ranges
Fast and efficient charging
Safety and protection mechanisms
Versatility and adaptability

The aforementioned technical requirements are of great relevance when it comes to designing effective and practical chargers for mobile electrical applications. This allows mobile devices to be charged reliably and efficiently and ensures maximum usability.

Compatibility with different battery types

Mobile electrical applications use a variety of battery technologies such as lithium-ion, nickel-metal hydride (NiMH) or lead-acid. Chargers must be able to charge different battery types accordingly. They should have suitable charging algorithms that are specifically adapted to the respective battery technology.

Flexible charging power and voltage ranges

Mobile applications can have different power requirements and voltage ranges. Chargers should be able to adjust the charging power accordingly, i.e. cover the appropriate voltage range. This makes it possible to charge both low-capacity and high-performance batteries.

Fast and efficient charging

Mobile applications often require short battery charging times to maximize uptime. Chargers must therefore have a high charging efficiency in order to minimize energy losses during the charging process and ensure efficient charging.

Security and protection mechanisms

Chargers for mobile applications must have various safety functions to ensure safe charging. These include protection mechanisms against overcharging, overheating, short circuits and overcurrent. Integrated circuits monitor the voltage, for example, and automatically control the charging process when certain values are reached.

Versatility and adaptability

Mobile applications cover a wide range of devices and requirements. Chargers should therefore enable maximum compatibility with devices and connections.

Power electronics

Intelligent DC systems

High voltage DC-DC converter

Innovative solution for quick & easy integration

Low voltage DC-DC converter

Low-voltage direct current converter - modular & versatile

Conclusion

efficient, flexible & secure

Incap stands out as a leading supplier of charging technology and battery management systems, particularly in the area of customized solutions for different voltage requirements from 12 to 1000 VDC.
Chargers offer not only flexibility and adaptability, but also comprehensive diagnostic capabilities for precise control and optimal charging of battery packs.
From onboard charging technology for electric vehicles to industrial UPS systems and mobile electrical applications, these chargers are characterized by their robustness, reliability and safety.

Questions about charging technology and chargers

CAN (Controller Area Network) is a serial bus system that was specially developed for communication between control units in vehicles. It enables reliable and fast communication between different components, such as engine control units, brake control units and other electronic systems in the vehicle. CAN is known for its robustness, as it is immune to interference and works well in environments with electromagnetic interference. It is widely used in the automotive industry, but also in other applications where reliable communication between different control units is required.

Ethernet is a widely used network protocol that was originally developed for computer networks. In the context of chargers and electric vehicles, Ethernet is often used for communication between different components, such as chargers and vehicles. Ethernet offers high data transfer rates and is suitable for transferring large amounts of data. Compared to CAN, Ethernet is more susceptible to electromagnetic interference, but it is more suitable when it comes to transmitting large amounts of data.