The “Porsche” among e-charging stations

The storage-based HPC fast charging system consisting of a dispenser and an innovative 140 kWh booster charges e-vehicles with up to 320 kW charging power in record time. © ADS-TEC
The storage-based HPC fast charging system consisting of a dispenser and an innovative 140 kWh booster charges e-vehicles with up to 320 kW charging power in record time. © ADS-TEC

The HPC Booster and Dispenser fast charging system from ADS-TEC Energy charges Porsche electric vehicles with enormous power. In this way, the charging times approach those of normal refueling processes. The company has brought the experts from H. P. Kaysser on board as a partner for the reliable housing production of the memory. These ensure that, in the current major order, Porsche drivers all over the world can charge their Taycan electric sports car in record time – and from an ordinary power connection.

“We are pleased to be able to make an important contribution to such a major order from such a renowned customer as a reliable and experienced partner from the region,” emphasises Thomas Kaysser, Managing Director of H. P. Kaysser from Nellmersbach. His company manufactures the storage unit of a new fast charging station from ADS-Tec. The company, in which Bosch also holds a stake, has developed the HPC storage-based fast charging system, which can charge e-vehicles with 320 kW of charging power in record time. This means that charging times for e-vehicles are almost as short as for a normal refuelling process. HPC consists of a charging station called “Dispenser” and a 140 kWh storage “HPC-Booster”, which stores and quickly releases the charging energy. HPC draws its power from an ordinary low-voltage power connection. Currently, around 500 stations are produced for Porsche drivers all over the world.

A buffer enables short loading times

But that is not all that H. P. Kaysser contributes. Because the leading medium-sized sheet metal processing company has always been thinking outside the box, the experts are already involved in the development phase. The sheet metal kit for one system includes 91 sheet metal parts, five welded assemblies and seven pre-assembly assemblies. In a specially provided hall, sheet metal parts and assemblies are assembled to form a housing with a base area of 1.5 x 1.5 metres and a height of about two metres. “There were many a tricky task to solve beforehand,” Kaysser recounts.

The double-walled and insulated lower part of the housing, which is later mostly hidden in the ground, houses alone the air conditioning for the 40 batteries each and the liquid-cooled charging cable. “We install several hundred meters of cables and hoses, all of which are tested for leaks and functionality before the booster housing is delivered,” emphasizes assembly manager Alexander Krammer. Each of the 40 battery compartments also has a cooling plate for air circulation. “This was one of the big challenges, how to accommodate that with these dimensions,” recalls Kaysser sales manager ppa. Frank Niedermaier. “Here we have found a much-appreciated solution.” In the upper part are the receptacles, holders and devices for batteries, pumps and computers. The integrated converter, energy management unit, security firewall and communication unit via mobile radio are also housed there, which ADS-TEC is final assembling in Dresden.

Energy suppliers and discounters interested in charging technology

ADS-Tec expects further orders for the intelligent, innovative fast charging system, for example from public utilities, energy suppliers, federal states, cities and municipalities as well as from large discounters offering fast charging while shopping. For ADS-TEC Managing Director Thomas Speidel, one thing is certain: “Fast charging is becoming the core element for functioning and widespread e-mobility. In many places, storage-supported high-performance charging at low voltage is the best solution for reasons of space and cost. And Thomas Kaysser adds: “We will gladly continue to contribute our expertise to innovative future topics that require a thinking manufacturing partner instead of an extended workbench”.