Why are high-voltage direct chargers mainly used on heavy-duty trucks and mining trucks now

The high-voltage direct hanging charger is said to be used to charge heavy trucks, mining trucks, and ports when turned on.

One of the core advantages of high-voltage direct mounted chargers is the ability to save transformers and directly draw power from the medium voltage grid. The traditional practice used to be that when 10kV electricity came in, it had to be first reduced to several hundred volts through a transformer, and then sent out through a charging module. The high-voltage direct hanging saves the voltage transformation in the middle section, theoretically increasing efficiency, reducing losses, and reducing volume.

However, in actual use, the manufacturer has reported some practical issues.

The power grid is a hurdle that cannot be bypassed. Many heavy-duty truck charging stations are built in mining areas, ports, or highway service areas, and in some places, the conditions of the medium voltage power grid are already average. The high-voltage direct hanging charger can pull a megawatt level power from 10kV at once, which has a significant impact on the power grid. Harmonic interference and voltage fluctuations may occur to some extent. After some stations are connected to high-voltage direct hanging equipment, the equipment of surrounding factories occasionally flashes and stops, which is not easy to solve.

Another aspect is the maintenance of power quality. There are a large number of power electronic devices working in the high-voltage direct hanging system. After long-term high load operation, harmonic control and reactive power compensation need to keep up. According to some sources, the AC/DC conversion of high-power charging equipment may generate 5-7 harmonics, and the voltage distortion rate may exceed the standard. Therefore, it is necessary to cooperate with certain filtering or compensation methods to deal with it.

Another factor is adaptability to the environment. In mining areas, there is a lot of ash, heavy salt spray corrosion in ports, and equipment casings are scorching hot from the sun in summer. The internal structure of high-voltage direct hanging equipment is more complex than that of ordinary chargers, and it is more sensitive to changes in dust and temperature. If the protection level and heat dissipation design are not good enough, it is easy to have some minor problems over time, which can be quite troublesome to maintain.

Some manufacturers are also developing corresponding products for this area. For example, Hongjiali(HG Power) provides 10kV/2.5MW high-voltage direct hanging split pile, which belongs to the megawatt level charging solution. According to the materials, its overall station efficiency can reach 97%, and the construction cost is reduced by about 35% compared to traditional solutions. This product uses 24 gun intelligent flexible distribution and occupies a relatively small area, making it suitable for centralized charging scenarios such as heavy trucks and mining trucks.

Overall, the high-voltage direct hanging method theoretically has many advantages over traditional methods, such as high efficiency, low losses, and less land occupation. But in actual implementation, it is still necessary to consider in advance the aspects of grid adaptation, power quality maintenance, and environmental adaptability. There are significant differences in the conditions of different venues, so it is recommended to learn more about several options for comparison and weigh them against the actual situation of one's own station.