Advanced Power Cabinet Design

 

1. Advanced Power Cabinet Design

The TRI-FLEX HubPower Cabinet represents a quantum leap in power conversion technology: 

• Industry-Leading Power Density: 512kW/m² footprint efficiency significantly exceeds competitive systems 

• High-Efficiency Liquid-Cooled AC|DC Modules: 50kW each, with modular expansion capability 

• Precision DC|DC Modules: 25kW each, enabling fine-grained power allocation 

• Scalable Capacity: Initial 800kW configuration expandable to 1.6MW without cabinet replacement 

• Full IP65 Environmental Rating: Complete protection against dust and water ingress, ensuring reliable operation in harsh conditions 

• Liquid Cooling Technology: Advanced thermal management provides consistent performance across temperature extremes while maintaining noise levels below 65dB (below 55dB in quiet mode) 

2. Ultra-Resolution Power Sharing

TRI-FLEX’s power sharing architecture offers unprecedented precision in power allocation: 

• 25kW Power Sharing Resolution: 2-3x finer granularity than competing systems (which typically offer 50-75kW resolution) 

• Dynamic Real-Time Allocation: Continuous optimization based on vehicle demand, state of charge, and available system capacity 

• Vehicle-Type Adaptive Distribution: Intelligent power allocation optimized for passenger vehicles, delivery vans, and heavy-duty vehicles simultaneously 

• Algorithmic Efficiency Optimization: Sophisticated load balancing algorithms maximize throughput while minimizing grid impact 

3. Extreme Scalability

The most distinctive technical characteristic of TRI-FLEX is its unmatched scalability: 

• Up to 64 Charge Port Connections: 8x more than conventional distributed systems, which typically max out at 8 ports 

• Modular Dispenser Options: 200kW and 400kW configurations available now, with scalability to 1MW+ dispensers forthcoming 

• Multiple Connector Standards: Support for CCS, NACS, and forthcoming MCS heavy-duty connectors 

• Smart DC Link Integration: Native compatibility with Battery Energy Storage Systems (BESS) and DC microgrids for grid-constrained sites 

4. Environmental Resilience

TRI-FLEX is engineered for extreme environmental durability: 

• Complete IP65 Rating: Fully sealed system for operation in dust, rain, snow, and coastal environments 

• Liquid-Cooled Design: Maintains consistent performance from -35°C to +50°C ambient conditions 

• Tested for >400,000 Cycles: Representing 10+ years of real-world usage 

• Redundant Critical Components: N+1 design principles applied to power modules, cooling systems, and communications 

Technical Comparison: TRI-FLEX vs. Conventional Distributed Systems 

To illustrate the technical advantages of TRI-FLEX, let’s examine several key performance metrics compared to current alternatives like Alpitronic’s Hypercharger system: 

Power Distribution Resolution 

The TRI-FLEX system’s 25kW power sharing resolution enables significantly more efficient utilization of available power. While competitive systems have moved from 75kW to 100kW power modules in their latest designs, TRI-FLEX provides 4x finer granularity. This precision becomes particularly valuable in mixed-fleet environments, where the difference between optimal and suboptimal power allocation can significantly impact charging time and energy costs. 

For example, with a 75kW resolution system, a vehicle requiring 110kW would typically receive either 75kW (underutilizing the vehicle’s charging capability) or 150kW (potentially wasting 40kW of capacity). TRI-FLEX can allocate precisely 125kW, matching vehicle requirements with minimal waste. 

Dispenser-to-Power Cabinet Ratio 

The most striking technical differential is dispenser scalability. Current systems, such as Alpitronic allow up to 8 charging points from a 1MW cabinet, TRI-FLEX enables up to 64 charging connections from a similarly sized 1.6MW system. This 8x improvement in connection density fundamentally transforms deployment economics and space utilization. 

This ultra-scaling capability is enabled by TRI-FLEX’s distributed power architecture, which uses a common DC bus to connect multiple power cabinets and dispensers in a flexible network topology. The system’s intelligent power management algorithms dynamically optimize power allocation across this network, ensuring each vehicle receives optimal charging power based on its specific requirements and the overall system load. 

Environmental Protection and Thermal Management 

TRI-FLEX’s fully liquid-cooled design and IP65-rated enclosures represent significant advancements over competing systems, many of which utilize forced-air cooling and achieve lower IP ratings. The liquid cooling system maintains optimal operating temperatures even in extreme ambient conditions, while the sealed enclosures prevent dust, moisture, and contaminant ingress that could otherwise compromise system reliability. 

This advanced thermal management also enables quieter operation—a critical consideration for residential-adjacent installations. At <65dB standard operation and <55dB in quiet mode, TRI-FLEX offers significantly reduced noise pollution compared to air-cooled alternatives. 

BESS and DC Microgrid Integration 

A key architectural advantage of TRI-FLEX is its native integration with DC power sources through the forthcoming Smart DC Link. This capability enables direct connection to: 

• Battery Energy Storage Systems (BESS) 

• Solar PV arrays with DC output 

• DC microgrids 

• Other distributed energy resources 

This integration eliminates the efficiency losses associated with DC-AC-DC conversion typically required when connecting these resources to conventional charging systems. By maintaining a DC architecture end-to-end, TRI-FLEX can achieve system-level efficiencies exceeding 95%, compared to 85-90% for solutions requiring multiple conversion stages. 

Technical Implementation Advantages 

The technical superiority of TRI-FLEX translates into several concrete implementation advantages: 

1. Grid Connection Optimization

TRI-FLEX’s architecture enables optimal utilization of available grid capacity by: 

• Precisely matching power draw to actual vehicle requirements 

• Intelligently distributing available power across multiple vehicles 

• Supporting demand response capabilities for grid stabilization 

• Enabling direct integration with renewable and storage resources 

For example, a site with a 1MW grid connection using conventional systems might support 2-4 high-power charging points. The same connection with TRI-FLEX could support 16+ charge points through intelligent power sharing, dramatically improving infrastructure utilization. 

2. Future-Proof Expandability

The modular nature of TRI-FLEX provides unprecedented expansion flexibility: 

• Start with essential 800kW infrastructure and scale to 1.6MW as demand grows 

• Add dispensers incrementally without replacing power cabinets 

• Upgrade to support new connector standards and vehicle types 

• Integrate with emerging technologies like stationary storage and renewable generation 

This technical architecture ensures that initial investments remain viable as technology and market needs evolve, eliminating the “rip and replace” cycle common with less flexible systems. 

3. Vehicle Type Flexibility

TRI-FLEX’s advanced power management enables simultaneous support for diverse vehicle types: 

• Passenger vehicles (50-350kW) 

• Light commercial vehicles (50-150kW) 

• Heavy-duty trucks (up to 1MW+) 

• Transit buses and other specialized vehicles 

By dynamically allocating power based on vehicle capabilities and charging profiles, TRI-FLEX maximizes throughput and efficiency across mixed fleets—a critical capability as electrification expands beyond passenger vehicles. 

Technical Evolution and Roadmap 

The TRI-FLEX architecture has been designed with a clear technical evolution path: 

• Current Capabilities: 800kW cabinet, up to 8 charging points, 200kW and 400kW dispensers 

• Near-Term Evolution: 1.6MW cabinet, up to 16 dispensers, Smart DC Link 

• Future Capabilities: 1.6MW cabinet supporting up to 64 charging points, 1MW+ dispensers, MCS connectivity 

This roadmap ensures that deployments remain technologically current without requiring wholesale replacement of installed infrastructure. 

Conclusion: The Technical Imperative for Ultra-Scaling Architecture 

As electric vehicle adoption accelerates globally, charging infrastructure must evolve beyond the architectural limitations that constrained first-generation systems. Alpitronic and other manufacturers have made significant advances with distributed architectures, but TRI-FLEX represents a fundamental leap forward with its ultra-scaling approach. 

The technical differentiators—25kW power sharing resolution, support for up to 64 charging points, liquid-cooled design with full IP65 rating, and native DC resource integration—combine to create a platform that not only meets current requirements but is engineered for the demands of mass-market EV adoption. 

For system architects, fleet operators, and charging network designers, TRI-FLEX offers the technical foundation to build truly future-proof infrastructure—infrastructure that can scale seamlessly as demand grows, adapt to evolving vehicle requirements, and integrate with the broader energy ecosystem. 

In the final analysis, ultra-scaling distributed architecture isn’t merely an incremental improvement; it’s a paradigm shift that aligns charging infrastructure capabilities with the exponential growth trajectory of electric mobility.