Heavy-Duty EV Charger Core

• Case Study: How a German Heavy-Duty EV Manufacturer Tamed 800V EMI with the JHNO71.5*29.6*30.0 Core

  

  Jan 13, 2026

  Germany's automotive engineering sector is world-renowned for its uncompromising standards, especially in the emerging sector of 800V Heavy-Duty Electrification. Recently, a Munich-based Tier-1 supplier for electric trucks faced a critical hurdle in their 350kW Fast Charging Unit design. This case study explores how our JHNO71.5 provided the high saturation and thermal resilience needed to handle extreme currents where standard Ferrite failed. The Challenge: "The 800V Heat Trap" The German engineering team was developing a high-power DC/DC converter for an electric semi-truck. The shift from 400V to an 800V architecture meant faster charging, but it also brought severe EMI challenges and massive heat generation. Saturation at Peak Load: The charging currents exceeded 400A. Traditional ferrite cores saturated instantly, losing inductance and allowing EMI noise to breach VDE standards. Limited Cooling: The busbar layout was tight. The core needed to handle high DC bias without requiring an active cooling loop directly on the choke. Vibration & Stress: Unlike passenger cars, heavy-duty trucks generate significant vibration. The magnetic core needed superior mechanical protection. They needed a "Heavyweight" magnetic solution—robust, large, and thermally stable. The Solution: The Heavy-Duty JHNO71.5*29.6*30 We introduced the 30, a high-performance Iron-based Nanocrystalline core specifically dimensioned for high-power units. Why this specific core solved the problem: Massive Effective Area (Ae) for High Power:With an Outer Diameter (OD) of 71.5mm and a Height of 30mm, this core offers a significantly larger magnetic cross-section than standard 55mm cores. This prevents saturation even under the massive current spikes typical of heavy-duty charging cycles. High Bs (1.25T) vs. Ferrite:While Ferrite saturates at ~0.4T, our Nanocrystalline material maintains linearity up to 1.25 Tesla. This allowed the German team to reduce the physical size of the filter by 50% compared to a ferrite stack, fitting perfectly into the IP67 aluminum housing. Broadband Attenuation (10kHz - 30MHz):The core provided exceptional insertion loss across the critical frequency spectrum, ensuring the 800V system passed the stringent CISPR 25 Class 5 and commercial vehicle EMC standards (ISO 7637). Thermal Endurance:Operating in a gearbox-adjacent environment, the core's stability from -40°C to +140°C (Curie temp 570°C) ensured zero performance degradation during long-haul climbs in summer heat. Robust "German-Grade" Packaging To meet the vibration requirements of the truck industry, the JHNO71.5*29.6*30.0 is encapsulated in a reinforced PBT (UL94-V0) Case. This square-profile casing protects the nanocrystalline ribbon from mechanical shock and mounting pressure, ensuring the permeability remains constant over the vehicle's 15-year lifecycle. The Outcome: Production Ready By integrating the JHNO71.5*29.6*30.0, the client achieved: 30% Volume Reduction in the EMC filter stage. Full Compliance with 800V EMC regulations without additional shielding. Thermal Safety: The core runs cooler due to lower hysteresis losses compared to alternative metal powder cores. ConclusionIn the era of 800V heavy-duty EVs, "standard" magnetic components are no longer enough. The 30 Nanocrystalline Core offers the brute strength (High Bs) and precision (High Permeability) required by German engineering standards. For more details, check: https://www.amorphousoem.com/product/jhno71529630-nanocrystalline-common-mode-choke-core-for-ev-power-units

  Hot Tags : High Power Nanocrystalline Core High Saturation Flux Density Core (1.25T) High Current EMI Filter Core Heavy-Duty EV Charger Core Iron-Based Nanocrystalline Tape Wound Core Thermal Stable Toroidal Core (-40°C to 140°C)

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