CRRC Group (China Railway Rolling Stock Corporation Limited — largest supplier of rail transit equipment in the world, ranked among the Fortune Global 500) has proposed custom development for the mining vehicle fleet scenario, which imposes stringent requirements on charging stations: high protection, high charging power, and rugged durability. These charging stations are mainly used for the client’s mining vehicles, with a single-gun configuration and high power output design.
In the harsh mining environment, charging stations must simultaneously meet multiple strict requirements for high protection, high power, and high reliability. They also need to adapt to the single-connector, high-power charging mode dedicated to mining vehicles, which poses high technical challenges in product design, hardware manufacturing, and system stability.
Appearance of CRRC Mining Vehicle Charging Station
With the rapid growth of high-power EV charging demand, traditional solutions that rely on increasing current levels face limitations such as oversized charging cables, increased thermal management requirements, and reduced user convenience. High-voltage charging technology provides a more efficient solution by increasing voltage rather than relying solely on higher current, enabling higher power delivery with improved system efficiency.
XYDF’s high-voltage ultra-fast charging system delivers 400 kW total power, supporting up to 250 A per connector and a wide 200–1600 V DC output range. It is designed for demanding applications such as commercial fleets, highway charging hubs, and next-generation high-power electric vehicles.
The core AC-DC power conversion unit features a modular architecture with 50 kW power modules, supporting flexible configuration and scalable power output. Equipped with fully digital control and CAN communication capabilities, multiple modules can operate in parallel with active current sharing to ensure balanced power distribution. The modular design enables rapid capacity expansion, easier maintenance, and enhanced system availability.
The single connector is designed for a 250 A max output current and a 400 kW max output power. The charging cable is engineered to withstand -40 ℃ ultra-low temperature, making it applicable to most low-temperature scenarios and meeting the requirements of the majority of charging operation conditions.
Tailored to the harsh environmental demands of steel plants, mines, ports and other special sites, the cabinet is designed with an IP55 protection rating. It can prevent the ingress of fine dust particles from all directions without affecting the normal operation of the equipment, and withstand low-pressure water jetting from any angle under normal working conditions without sustaining damage.
A centrifugal fan is adopted as the primary cooling solution, combined with an optimized air duct design. The air inlet and outlet are configured with independent air channels to improve airflow efficiency and heat dissipation performance.
The cooling capacity is determined based on the total heat generation of the power modules. By leveraging proven thermal design experience from mass-produced models, the system ensures reliable heat dissipation performance even under high-temperature operating conditions.
For safety protection, the EV charging station is equipped with a smoke detection system. If the smoke concentration exceeds the preset threshold due to equipment failure, the control system will automatically disconnect the control power supply and activate a visual alarm to prevent potential fire hazards.
In addition, a water intrusion alarm is integrated into the EV charging station to further enhance operational safety and reliability.
Developed in accordance with the client’s dimensional requirements and based on our existing product, the EV charging station adopts ceramic high-voltage DC contactors, tempered glass panels with light boards, insulating protection plates, and optimized copper busbar design. The internal layout of electrical components, as well as the cooling and protection designs, have all been upgraded and optimized.
Structural Design of CRRC Mining Vehicle Charging Station
After deployment, the 400 kW high-power output and wide voltage range significantly improve charging efficiency and reduce charging time. With IP55 protection, -40℃ low-temperature resistance, and an efficient thermal management design, the charging station is well suited for harsh mining environments, enabling reliable all-weather operation.
Built with high-quality components and multiple safety protection mechanisms, the system delivers enhanced durability, stability, and operational safety. It helps reduce maintenance requirements, minimize operating costs, and improve the overall reliability of charging operations.
Xinya Dongfang Electricity Technology Co., Ltd.
