Low-cost fast-charging stations often result in increased electrical energy consumption, primarily due to the following reasons:
1. **Poor Quality Components**: To reduce costs, low-cost fast-charging stations may use low-grade components, such as non-fire-retardant cables, poor-quality transformers, and capacitors. These components have higher inherent resistance, and according to Joule's Law (\(P = I^{2}R\)), they generate more heat when carrying high currents, leading to energy loss. Additionally, their IGBT modules may have lower efficiency, with AC/DC conversion rates as low as 88%. For example, using an IGBT module with 92% efficiency and a conversion rate of 88% can result in energy losses of up to 12%. In contrast, premium charging stations use SiC modules with 97% efficiency and 95% conversion rates, resulting in energy losses as low as 5%.
2. **Design and Manufacturing Flaws**: Some low-cost fast-charging stations may omit critical safety devices like AC contactors and overcurrent protection, or skip mandatory EMC (Electromagnetic Compatibility) testing as per national standards. This can expose the charging station to electromagnetic interference during operation, degrading performance and increasing energy consumption. Furthermore, cost-cutting measures that simplify the cooling system can lead to inadequate heat dissipation, causing internal temperature rises, accelerated component aging, and increased energy losses.
3. **Power Rating Misrepresentation**: Low-cost stations may use non-mainstream or refurbished modules, or reduce the number of modules, leading to power rating misrepresentation. For instance, a low-cost station labeled as 120kW may only deliver around 84kW. Users would need longer charging times to achieve the same charge, resulting in increased energy losses during the extended operation.
4. **Poor Compatibility and Adaptability**: Low-cost stations often cannot integrate with major platforms, have fixed hardware that cannot be upgraded, and lack features like remote monitoring and load forecasting. This limits their adaptability to different vehicles and grid conditions, preventing optimization adjustments based on actual conditions, which can lead to low charging efficiency and increased energy consumption. Additionally, their narrow operating temperature range can result in performance degradation and higher energy losses under extreme weather conditions.