A Review of Modular Converter Designs for MW Level Charging of Heavy-Duty Electric Vehicles

This paper reviews modular power converter architectures and control strategies for megawatt-level (MW) electric vehicle (EV) fast charging systems. Two main topologies-Common DC Link (CDCL) and Isolated DC Link (IDCL)-are compared in terms of scalability, fault tolerance, and control complexity. Key submodule (SM) topologies for AC/DC and DC/DC stages are evaluated, with a focus on bidirectional operation and switching performance. A distributed control approach is discussed, addressing synchronization and communication challenges in modular systems. To support safe and efficient development, the role of hardware-in-the-loop (HIL) testing and scaled-down prototypes is emphasized. Together, these tools bridge the gap between simulation and deployment, enabling reliable validation of control strategies and accelerating the deployment of robust, high-power EV charging infrastructure.