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Products Power Conversion Engineering Specifically matched for Chicago’s automotive OEMs, charging infrastructure builders (EVSE), heavy commercial transit, and industrial automation equipment.
Compact switching adapter engineered for EVSE diagnostic ports, charging post logic control modules, and outdoor gateway nodes.
Ultra-low ripple regulated AC/DC converter ideal for EV Battery Management System (BMS) microcontrollers and sensor sub-bus lines.
Rugged galvanically isolated linear transformer designed for industrial EV charging grid monitoring and harsh EMI environment isolation.
Industrial-grade power converter with dynamic load response, customized for fleet maintenance diagnostics and mobile EV testing units.
High-reliability power unit engineered for vehicle telematics consoles, dashboard displays, and commercial transit fleet computing systems.
Scalable wide-output current adapter built for commercial EV charging controllers, robotic arm actuators, and material handling vehicles.
Flexible DC power platform allowing precise voltage trimming for autonomous vehicle sensor arrays, LiDAR modules, and camera vision systems.
Ultra-compact auxiliary power module engineered for commercial EV charging access card readers, touchscreens, and payment terminal systems.
Architecting thermal resilience, high-voltage galvanic isolation, and EMC compliance for the Midwest's largest transportation, logistics, and manufacturing hub.
Chicago’s severe winter environment presents harsh operating conditions for Electric Vehicles (EVs) and EV Supply Equipment (EVSE). During winter months, temperatures routinely drop to -20°F (-29°C), placing severe thermal stress on power semiconductors, electrolytic capacitors, and magnetic cores. Commercial power supplies that perform adequately in controlled climates often suffer from cold-start failures, excessive voltage sag, or thermal shock damage in Northern Illinois.
At Wall Industries, our Exeter, New Hampshire engineering team designs modified-standard and custom EV power supplies utilizing premium grade, sub-zero rated components. We implement silicone encapsulation potting and conformal coating to protect circuitry from condensation during rapid freeze-thaw cycles. Our power topologies—including high-efficiency LLC resonant converters and active PFC front-ends—are rated for full operation down to -40°C to +85°C without derating, ensuring zero downtime for Chicago fleet vehicles and public transit chargers.
Strategic alignment with the Illinois Climate and Equitable Jobs Act (CEJA) and NEVI infrastructure mandates.
Under the Illinois Climate and Equitable Jobs Act, thousands of Level 2 and Level 3 DC Fast Chargers are being deployed along the I-90, I-94, and I-55 corridors. Our power supplies meet strict utility grid transient immunity requirements (IEEE 519 and ANSI C84.1), ensuring compatibility with ComEd’s electrical grid throughout Cook, DuPage, and Will counties.
For Chicago OEM vehicle manufacturers, functional safety is non-negotiable. Wall Industries engineers power conversion architectures designed to assist compliance with ISO 26262 ASIL ratings, featuring dual-redundant over-voltage protection (OVP), hardware thermal shutdown, and galvanic isolation up to 8 kVDC.
To maximize vehicle range and minimize payload weight, our latest DC/DC converters incorporate Silicon Carbide (SiC) power MOSFETs. This yields conversion efficiencies exceeding 96%, allowing midwestern commercial vehicle fleets to operate longer distances on a single charge while generating minimal waste heat.
Compare standard and custom design capabilities for Chicago OEM system integrators.
| Platform Series | Input Voltage Window | Output Voltage / Power | Isolation Rating | Operating Temp | Primary EV Application |
|---|---|---|---|---|---|
| High-Voltage Auxiliary DC/DC | 250 – 900 VDC (EV Bus) | 12V, 24V, 48V (Up to 1.5kW) | 4,000 VAC / 5.6 kVDC | -40°C to +105°C | On-board chassis control, steering pump, HVAC |
| EVSE Auxiliary AC/DC | 85 – 305 VAC Universal | 5V, 12V, 24V (15W to 300W) | 3,000 VAC Reinforced | -40°C to +85°C | DC Fast Charger logic, RFID, liquid-cooling pumps |
| Battery Management DC/DC | 4:1 Wide (9 – 36 VDC) | 3.3V, 5V, 12V Dual Output | 1.5 to 8 kVDC High Isolation | -55°C to +125°C | Cell balancing monitors, telematics, CAN bus nodes |
| Heavy Transit Linear Series | 110 / 230 VAC Nominal | 9VAC, 12VAC, 24VAC (Up to 50W) | 2,500 VAC Line Isolation | -25°C to +70°C | Grid sub-metering, station access control gate switches |
| Level VI External Chargers | 90 – 264 VAC 50/60Hz | 5V to 48V DC (Desktop/Plug) | 3,000 VAC Primary-Sec | 0°C to +45°C | Maintenance handheld diagnostic units, fleet scanners |
Founded in 1961 in Exeter, New Hampshire, Wall Industries, Inc. brings over 60 years of specialized power conversion expertise to Chicago’s rapidly expanding electric vehicle ecosystem. Unlike off-the-shelf catalog distributors, we combine local engineering consultation with flexible manufacturing.
Whether your project requires a minor tweak to an existing catalog part (modified-standard) or a ground-up custom power supply design engineered to exacting space and thermal constraints, our experienced power design engineers guide you from initial topology selection through qualification testing and high-volume export release.
Addressing key logistical, technical, and compliance inquiries from local OEM procurement managers.
Our cold-weather EV power supplies feature extended ambient temperature ratings down to -40°C (with optional -55°C capability on request). We utilize military-grade ceramic capacitors, low-ESR solid polymer capacitors, and silicone potting compound to prevent cold-start latch-up and moisture ingress caused by freezing condensation. Additionally, our baseplate conduction cooling options eliminate failure-prone mechanical cooling fans.
With primary engineering and production facilities located in Exeter, New Hampshire, standard catalog and modified-standard evaluation samples can be delivered to the Chicago metropolitan area within 3 to 5 business days. Production volume orders benefit from established logistics corridors directly to Illinois manufacturing plants, avoiding overseas port delays.
Yes. A major advantage of working with Wall Industries is our modified-standard engineering service. We routinely modify cable lengths, add automotive-grade sealed connectors (such as Deutsch or Amphenol), adjust output voltage trim levels, and apply specialized conformal coatings without requiring complete redesign of the underlying safety-certified circuit board.
Depending on your application target, our designs meet or exceed safety and EMC standards including UL 62368-1, IEC 60601-1 (medical/ambulance EVs), EN 50155 (rail/transit), FCC Part 15 Class B / CISPR 32 emissions limits, SAE J1772 for charging interfaces, and DoE Level VI efficiency requirements for external power supplies exported globally.
If your project specifications (input voltage range, output power, safety isolation) fit closely within one of our 3,000+ catalog models, a modified-standard approach is fastest and most cost-effective. If your design requires non-standard mechanical dimensions, multi-channel dynamic load management, or specialized MIL/Automotive environmental testing, our engineering team can execute a fully custom design program from scratch.
Yes. All of our commercial and EV power products strictly comply with US export controls (EAR/ITAR compliance where applicable), RoHS, and REACH directives. We provide complete documentation support including Certificate of Origin, CE declarations, and CB scheme test reports for seamless international export.
Speak directly with our applications engineering team in Exeter, NH. We will review your electrical schematics, mechanical requirements, and thermal constraints to deliver an optimized solution on schedule.
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