Battery-Boosted EV Charging Components: How They Work Together for Seamless Charging 

Electric vehicles are increasingly becoming part of our everyday life. They’re cleaner and cheaper to run than traditional cars. But while the vehicles themselves are ready, the infrastructure around them is still in a growing phase. One of the biggest challenges at the moment? Growing requirements of Fast/Ultra-Fast Charging. As you are aware, ultra-fast charging an EV on a very rudimentary level depends on the stable and powerful supply of high-voltage electricity. During peak demand, grids can become overloaded, slowing down charging times and increasing costs. That’s where Battery Boosted EV Chargers, or BBECs, come in. They’re designed to bridge this gap—offer faster, more reliable charging by combining energy storage with smart distribution. But how is this outcome achieved? Let’s look at how Battery boosted EV charger technology works, through its components in order of storage and flow of electric current.

Key Components of a Battery Boosted EV Charger (BBEC):

The components of a BBEC, in order of storage and flow of current can be divided into 4 parts  

• The Battery Module 

• Power Conversion System 

• Auxiliary Architecture 

• Monitors and Controls 

1. Battery Module: The Energy Reservoir

Think of your EV charging station as a busy café during rush hour. Now, imagine the café has a well-stocked pantry filled with snacks ready to go. This pantry is like the battery in a battery-boosted system.  Most EV charging batteries use lithium-ion technology because of their high energy density and efficiency. These batteries store direct current (DC) and generally use two energy sources for this purpose: AC grid, and solar. They store energy during off-peak hours from grids, and in peak sunlight hours. They then distribute it during the busiest times. This way, the grid doesn’t get overwhelmed, electricity costs remain under control, and customers get their vehicles charged quickly and reliably.

2. Power Conversion System (PCS): The Energy Translator

Electricity stored in the battery is direct current (DC), but most EV chargers and the grid operate on alternating current (AC). The Power Conversion System (PCS) is a bi-directional inverter that converts AC to DC when charging the battery and when powering the EV. It can also convert DC to AC and send power back to the main grid to stabilize it, creating additional potential business opportunities for CPOs. 

The PCS also manages voltage and frequency to keep power quality high and energy losses low. It’s a highly efficient unit that ensures electricity flows smoothly between the battery, grid, and charging points. 

3. Auxiliary Architecture: The Electrical Backbone

Electricity needs a reliable and safe path from the grid and battery to the EV. This is supported by auxiliary architecture, which includes: 

• Transformers that adjust voltage levels to what the chargers need. 

• DC switch between PCS and battery, AC breaker between PCS and AC transformer for safety.   

• High-quality cables that safely carry large currents without energy loss. 

• Rectifiers and filters that clean and regulate power flow. 

Together, these parts form the backbone that delivers power efficiently to your customers’ vehicles. 

4 Monitors and Controls: The System’s Brain

A BBEC has sensors and software systems that monitor voltage, current, and temperature. They detect any anomalies early, like overheating cables or voltage fluctuations, so that the system can adjust operations and/or trigger safety measures immediately.  Here are the system controls that a good BBEC has- 

4.1. Battery Management System (BMS): The coordinator

The Battery Management System (BMS) is a smart controller that keeps the battery healthy and safe. It monitors each cell’s voltage, current, and temperature to: 

• Prevent overcharging or deep discharging 

• Balance charge across cells for longer battery life 

• Manage thermal conditions through cooling or heating 

• Communicate battery status to the overall system 

This ensures your batteries perform optimally and safely over their lifetime.

4.2. Dynamic Load Management (DLM): The Traffic Cop

When multiple EVs charge simultaneously, the total power demand can exceed what your site can safely handle. This is where Dynamic Load Management (DLM) steps in. DLM continuously monitors total power consumption at the site and dynamically adjusts the charging power delivered to each EV. It ensures that each EV is charging at a reasonable speed, and the combined power demand stays within safe limits, preventing overloads and power outages. 

There are three main approaches to DLM: 

• Load Levelling: Sets a maximum total power limit and distributes available power evenly among all charging EVs. 

• Adaptive Load Management: Controls power at each charger based on real-time demand and usage. 

• Site Responsive Load Management: Automatically adjusts charging power to stay within the site’s electrical capacity. 

The benefit? EVs still get charged as fast as possible without tripping breakers or causing voltage dips. DLM also helps reduce peak demand charges, saving you money. 

4.3. Energy Management System (EMS): The Master Coordinator

The Energy Management System (EMS) optimizes how energy flows through the entire system. It analyzes usage patterns and coordinates between the battery, grid, renewable sources, and charging points to maximize efficiency and reduce costs. 

The EMS decides when to store energy in the battery (for example, during off-peak hours or when solar power is abundant) and when to release it to meet charging demands. It thus helps stabilize the grid by smoothing out peaks and valleys in energy consumption. The EMS ensures you get the most out of your infrastructure, reducing reliance on expensive grid upgrades and lowering operational costs. 

4.4. Safety Features Built into Battery Boosted EV Chargers: for protecting People and Equipment

4.4.1. Thermal Management System (TMS): Keeping Cool Under Pressure 

Charging and discharging batteries generate heat, which can reduce performance and even cause thermal runaway – a chemical chain reaction in the battery that leads to malfunction and damage to the equipment. The Thermal Management System (TMS) keeps battery temperatures in the safe zone using Heating Ventilation and Air Conditioning (HVACs) or liquid cooling. Thermal sensors are also linked to automatic shutdown functionalities if temperatures rise dangerously. 

4.4.2. Fire Safety Systems: Guarding Against the Worst 

Batteries are flammable, which is why modern battery-boosted EV chargers incorporate advanced fire safety systems such as: 

• Thermal monitoring and early warning sensors to detect heat anomalies before it escalates. 

• Fire-resistant materials and strategic station layouts to prevent the fire from spreading. 

• Aerosol and sprinkler systems that quickly extinguish fires at the source with minimal residue. 

• Specialized fire extinguishers, designed for lithium-ion battery fires. 

These systems protect your infrastructure, customers, and property, especially in enclosed or high-density charging areas. 

Apart from these features, a safe BBEC also includes:  

• Circuit breakers and fuses that cut power during faults 

• Emergency shutoff switches for quick disconnection 

• Overvoltage, undervoltage, and overcurrent protection. 

How It All Comes Together

When an EV plugs in: 

• Electricity flows from the grid and/or solar panels. 

• Excess energy charges the battery via the PCS, converting AC to DC in case of grid usage. Solar power is DC by default. 

• When the EV demands power, the battery discharges, with the PCS converting DC back to AC. 

• Transformers convert electricity to appropriate voltage using step-up or step-down mechanisms. 

• Sensors monitor each of these stages, feeding data to the EMS, BMS, and TMS. 

• The BMS manages battery health and safety. 

• The TMS keeps battery temperatures optimal. 

• The EMS optimizes electricity flow and source usage. 

• The DLM balances power across multiple charging points to prevent overload. 

• Safety switches and fire protection systems stand guard, ready to act if anything goes wrong. 

• Cables deliver electricity safely to the EV. 

This teamwork means you get fast, reliable charging without costly grid upgrades. Voltage fluctuations and outages are minimized, enabling your charging station to handle a high number of vehicles efficiently.

Final Thoughts  

Battery-boosted EV charging systems are more than just batteries and plugs. They’re integrated solutions that enable you to save money, boost reliability, and scale easily, while going green. As a CPO, understanding the architecture of a BBEC helps you see why it’s a smart, future-proof investment that meets growing EV charging demands while protecting your bottom line. 

Exicom’s Harmony Boost combines perfectly matched, high-quality components, a high efficiency battery with intelligent Energy and Load Management Systems. This modular design ensures fast, reliable charging while maximizing renewable energy use.  If you want to offer your customers a smooth, powerful charging experience and secure your investment for years to come, get in touch with us here.

Glossary 

• BESS (Battery Energy Storage System): A system that stores electrical energy in batteries, often combining renewable sources like solar or wind with the grid, to provide stable, on-demand power for EV charging and grid support. 

• BBEC (Battery-Boosted EV Charger): An EV charging system enhanced with integrated battery storage to deliver fast, reliable charging while reducing grid strain and enabling better energy management6. 

• CPO (Charge Point Operator): The entity responsible for owning, managing, and operating EV charging stations, ensuring maintenance, billing, and reliable service for EV users. 

• BMS (Battery Management System): Monitors and protects battery health by managing charging, voltage, and temperature. 

• PCS (Power Conversion System): Converts electricity between AC (Alternating Current) and DC (Direct Current) to match battery and grid requirements. 

• TMS (Thermal Management System): Controls battery temperature to maintain safe and efficient operation. 

• DLM (Dynamic Load Management): Technology that balances charging power among multiple EVs to avoid exceeding electrical limits. 

• EMS (Energy Management System): Software that manages energy sources and storage for optimal performance and cost savings.

Bibliography 

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2. Power Sonic. (n.d.). A Guide to Battery Energy Storage System Components. Power Sonic Blog. Retrieved April 30, 2025, from https://www.power-sonic.com/blog/battery-energy-storage-system-components/ 

3. Edina. (n.d.). Battery Energy Storage System (BESS) | The Ultimate Guide. Edina Power. Retrieved April 30, 2025, from https://www.edina.eu/power/battery-energy-storage-system-bess 

4. TROES Corporation. (n.d.). The Complexities of Integrating Battery Energy Storage. TROES Corp Blog. Retrieved April 30, 2025, from https://troescorp.com/beyond-solar-the-complexities-of-integrating-battery-energy-storage/ 

5. TLS Containers. (2024, May 19). Comprehensive Guide to the DC Components of a Battery Energy Storage System (BESS). TLS Blog. Retrieved April 30, 2025, from https://www.tls-containers.com/tls-blog/comprehensive-guide-to-the-dc-components-of-a-battery-energy-storage-system-bess 

6. Exicom. (2025, April 18). Smart CPOs Grow EV Charging Networks and Cut Costs with Dynamic Load Management. Exicom Newsroom. Retrieved April 30, 2025, from https://www.exicom.in/newsroom/smart-cpos-grow-ev-charging-networks-and-cut-costs-with-dynamic-load-management