Splitting the Power: How Dual-Plug EV Chargers Distribute Load (CCS1/CCS2)

As the adoption of electric vehicles (EVs) accelerates globally, Charge Point Operators (CPOs) and fleet managers face a critical challenge: maximizing station throughput without overhauling grid capacity. Enter the dual-plug DC fast charger—a cornerstone of modern EV charging infrastructure designed to service multiple vehicles simultaneously from a single grid connection.

But how exactly does a single charging station “know” how to divide its power between two high-capacity vehicles using CCS1 or CCS2 connectors? The secret lies in dynamic load distribution and advanced power electronics.

The Anatomy of a Dual-Plug DC Fast Charger

Before diving into load distribution, it is essential to understand the hardware. Dual-plug chargers typically feature either two CCS1 (Combined Charging System) cables for the North American market, two CCS2 cables for Europe and global markets, or a combination of both.

Unlike conventional AC chargers that rely on the vehicle’s onboard converter, DC fast chargers deliver direct current straight to the EV’s battery. To achieve this, the charging station houses an array of internal power modules.

At the core of this power conversion process are industrial-grade semiconductors. Drawing on PandaExo’s deep heritage in power electronics, highly efficient components like bridge rectifiers and IGBT/SiC modules are used to convert grid AC power into stable, high-voltage DC power. These internal modules are the building blocks that make power sharing possible.

The Mechanics of Power Splitting

When an EV plugs into a charger, it doesn’t just blindly receive power. The vehicle’s Battery Management System (BMS) establishes a communication link with the charger (via protocols like ISO 15118), negotiating the maximum voltage and current the battery can safely accept based on its current State of Charge (SoC), temperature, and capacity.

When two vehicles are plugged into a dual-plug DC fast charging station, the system must decide how to allocate its total available power. It generally does this in one of two ways:

1. Static Power Sharing (Fixed Split)

In older or more basic architectures, the charger divides its total power output evenly the moment a second vehicle connects.

• Example: If a 120kW charger has two EVs plugged in, it strictly assigns 60kW to Plug A and 60kW to Plug B.
• The Drawback: If EV “A” is at 90% SoC and only requesting 20kW, the remaining 40kW allocated to Plug A goes completely unused, while EV “B” is bottlenecked at 60kW despite being able to accept more.

2. Dynamic Power Sharing (Intelligent Routing)

Modern high-performance chargers utilize a dynamic matrix of power modules. Instead of a hardwired 50/50 split, the station’s smart energy management controller continuously evaluates the real-time demands of both vehicles and physically switches power modules to the cable that needs them most.

• Example: A 120kW charger is equipped with four 30kW power modules.
• Minute 1: EV “A” arrives with a low battery and requests maximum power. The charger assigns all four modules (120kW) to EV “A”.
• Minute 15: EV “B” arrives. The charger instantly reallocates two modules to EV “B”, resulting in a 60kW / 60kW split.
• Minute 30: EV “A” reaches 80% SoC and its demand drops to 25kW. The charger reassigns one of EV “A”s modules to EV “B”. Now, EV “A” receives 30kW (satisfying its 25kW demand), and EV “B” receives 90kW, drastically speeding up the overall charging process.

Commercial Benefits for Charge Point Operators

Implementing dual-plug chargers with dynamic load distribution offers distinct commercial advantages for CPOs, retail locations, and fleet depots:

• Maximized Grid Utilization: By intelligently routing every available kilowatt, operators ensure they are getting the maximum return on their available grid capacity without needing expensive utility upgrades.
• Lower CapEx per Port: Installing one 120kW dual-plug charger requires less trenching, wiring, and footprint than installing two standalone 60kW chargers, effectively halving the installation overhead.
• Increased Station Turnover: Dynamic sharing ensures vehicles spend less time waiting for a charge. Faster charging sessions mean higher daily throughput and increased revenue.
• Future-Proof Scalability: Stations utilizing modular power architectures can often be upgraded. A CPO could potentially add more power modules to the cabinet later to increase total output as EV battery capacities grow.

Elevate Your Infrastructure with PandaExo

Efficient power distribution is non-negotiable for profitable EV charging networks. At PandaExo, we leverage our 28,000-square-meter advanced manufacturing base and deep expertise in power semiconductors to engineer chargers that don’t just deliver power—they manage it brilliantly.

Whether you are looking to deploy intelligent dual-plug DC fast chargers for highway corridors or seeking customized OEM/ODM hardware for your brand, PandaExo provides the factory-direct scale and precision you need.

Ready to upgrade your EV charging network? Explore our complete hardware catalog today, or contact our engineering team to discuss customized smart charging solutions for your next project.