EV Charging
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ange anxiety is a common concern for electric vehicle (EV) owners. The fear of running out of power before reaching a charging station has, for years, held back EV adoption. But with advancements in charging technologies, there’s now a shining hope on the horizon: 800V high voltage systems. This cutting-edge tech promises to drastically cut charging times, increase driving range, and make EVs more practical for the everyday driver. Let’s dive into how 800V technology works, why it’s a game-changer, and how companies like MOREDAY are contributing to this shift.
In order to solve the above problems, in addition to increasing battery life by stacking batteries, technologies such as solid-state batteries and battery replacement are still difficult to achieve breakthrough progress due to cost factors. Therefore, “fast charging” and “super charging” have become the layout and research and development focus of various car companies, and the 800V high-voltage platform came into being.
Electric Vehicle High Voltage System
In the design of the electrical system of electric vehicles, the electrical system is usually divided into high voltage and low voltage parts according to the working voltage of the electrical system. The high voltage electrical system mainly includes components such as batteries, motors, electronic controls, and high voltage wiring harnesses; while the low voltage electrical system is the traditional instrumentation, lighting, entertainment system, windows, wiper system and other components.
The voltage platform of the high-voltage system comes from the output voltage of the vehicle’s power battery pack. The rated voltage of the high-voltage electrical system of most electric vehicles is between 300-500V, such as the voltage of Tesla Model Y is 355.2V, Volkswagen ID.4 is 352V, and Qin PLUS EV is 422.4V. The low-voltage electrical system still uses the traditional 12V or 24V voltage.
400V High Voltage System Features
The 400V voltage system usually includes: batteries, motors, electronic controls, chargers (OBC), high and low voltage converters (DC/DC), high voltage control boxes (PDU), connectors and wiring harnesses, and motor/battery thermal management related components.
Limited by the voltage resistance of silicon-based IGBT power components, high-voltage systems previously used a 400V voltage platform. The charging pile based on this voltage platform has a maximum charging power of 250kW and a peak working current of nearly 600A. If you want to increase the charging power and shorten the charging time, you need to increase the voltage platform from 400V to 800V, 1000V or even higher to expand the high-voltage system. The mass-produced 800V voltage platform of the Porsche Taycan has increased the maximum charging power to 350KW, and can charge a 93.4kWh power battery from 5% to 80% in 22.5 minutes, providing a range of 300 kilometers.
800V High Voltage System Features
To realize a full 800V high-voltage system, first of all, an 800V battery pack is needed to ensure that the output voltage meets the requirements. Secondly, all other parts in the high-voltage circuit, such as the motor, air conditioner, charger, DC/DC, related wiring harness, high-voltage connector, etc., must meet the 800V working requirements.
In order to be compatible with the 500V/750V fast charging piles on the market, 800V pure electric vehicles will be equipped with 400V to 800V boost DC/DC modules for quite a long time. Its function is to decide whether to activate the boost module to charge the 800V battery pack according to the actual voltage capacity of the charging pile.
According to the cost-effectiveness, there are roughly two types of forms:
One is the full 800V platform architecture, in which all vehicle parts are designed for 800V.
One is the cost-effective 800V platform architecture. Some 400V components are retained. Since the current cost of 800V power switching devices is several times that of 400V IGBTs, in order to balance the cost of the whole vehicle and the driving efficiency, the OEM has the motivation to use 800V components (such as motors) in the key and necessary drive systems and retain some 400V parts (such as electric air conditioners and DC/DC).
Advantages of 800V High Voltage System
From a technical perspective, the 800V high-voltage platform has the following significant advantages over the traditional 400V voltage platform: significantly improved charging speed, lightweight battery, and higher energy utilization efficiency.
Improve Charging Speed
800V technology can increase charging power by increasing voltage, thereby reducing charging time and bringing users a convenient user experience. So how does 800V increase charging speed?
In middle school physics knowledge, we have learned that power = voltage * current (P = UI). In other words, if you want to shorten the charging time of electric vehicles, you have to increase the charging power, and if you want to increase the power, you have to increase the voltage or current of the system. At present, most car manufacturers are promoting high voltage rather than high current. In other words, the solution of speeding up the charging speed of electric vehicles by increasing the current has not been widely recognized. The reason is actually very simple. In the laws of physics, the heat generation power of metal conductors = the square of the current * resistance (P = I²R). This means that when the conductor resistance remains unchanged, as the current increases, the heat generation of the system will increase exponentially, which will lead to overheating of the battery. And what does battery overheating mean, everyone should understand.
Reduce Battery Overheating Issues
As the charging power increases, the current will also increase, and excessive current may cause the battery to overheat. 800V technology avoids this problem by increasing the voltage, thereby protecting the health and life of the battery. In addition, from an energy consumption perspective, the heating of the battery pack and high-voltage wiring harness will also increase the power loss of the system. In contrast, using a higher voltage to increase the charging power not only achieves a faster charging speed, but also avoids the problem of overheating of the battery pack and even the charging pile.
Optimize Motor Design and Wiring Harness Layout
800V high voltage technology can reduce the number and length of wiring harnesses, reduce wiring harness losses and failure rates, and thus improve vehicle reliability and stability.
When the motor power is equal, the motor size of a vehicle built on a high-voltage platform is smaller than that of a vehicle built on a low-voltage platform. In other words, the high-voltage platform can increase the power density of the motor. From the perspective of motor production, the reduction in motor size also means lower costs.
In terms of wiring harness layout, theoretically, the larger the current, the thicker the wire is needed. However, according to the formula of power = voltage * current (P=UI), when the power is the same, the current will decrease as the voltage increases. Taking 400V and 800V as examples, at the same power, the current of 800V is only half of that of 400V. Therefore, after adopting the 800V high-voltage system, not only the heat generated by the battery and wiring harness is reduced, and the cost of battery thermal management is reduced, but also thinner wires can be used, the wiring harness is convenient to arrange, and the price is lower.
Reduce Vehicle Energy Consumption
800V high voltage technology can effectively reduce the operating temperature of the equipment and reduce energy loss caused by high temperature. By using high temperature resistant materials and technologies, such as silicon carbide (SiC), the energy consumption of the whole vehicle can be reduced and the energy utilization efficiency can be improved.
Extended Driving Range
The 800V high voltage technology enables the battery to operate at a high-power charging state, thereby achieving a longer driving range. For long-distance travel, it can help users replenish more power in a shorter time.
The Challenges of 800V Systems
It’s not all smooth sailing, though. Adopting 800V systems requires significant upgrades to charging infrastructure. Most of today’s public chargers are designed for 400V systems, meaning they’d need to be replaced or upgraded to accommodate the new technology.
Additionally, manufacturing costs for 800V-compatible components (like batteries and power electronics) are higher. This means the initial rollout of 800V vehicles could carry a higher price tag, which could deter budget-conscious consumers. However, as with most technologies, these costs are expected to drop as production scales up.
Then there’s the compatibility issue. Not all EVs will support 800V charging, especially older models. So, while newer cars might benefit from faster charging, the existing fleet may be left behind. This creates a potential market divide, though it also opens opportunities for innovative companies to create retrofitting solutions.
MOREDAY's Role in Advancing 800V Technology
As a leader in EV charging solutions, MOREDAY is at the forefront of this technological shift. Our focus on 800V-compatible charging infrastructure helps ensure that drivers worldwide can take advantage of faster, more efficient charging.
We’re developing next-generation charging stations that are not only 800V-compatible but also designed with sustainability and user experience in mind. Our stations will be equipped with smart energy management systems to optimize grid use, reducing strain on the electric grid during peak times. This means a more reliable and greener solution for the future of transportation.
At MOREDAY, we believe that the adoption of 800V high voltage technology will accelerate the global transition to sustainable electric mobility. By providing the infrastructure needed for this shift, we’re helping to make EVs a viable option for everyone, from city commuters to long-distance travelers.
Conclusion
The future of electric vehicles is bright, and 800V high voltage systems are lighting the way. By addressing the critical issue of charging time and range anxiety, this technology is set to revolutionize the EV landscape. Faster charging, more efficient energy use, and the potential for widespread adoption make 800V the next big thing in electric mobility.
As companies like MOREDAY continue to innovate and develop the necessary infrastructure, we’re moving closer to a world where electric vehicles are the norm, not the exception. Range anxiety? It’s on its way out the door.
popular questions
FAQ`s.
Q1: How much faster is 800V charging compared to 400V?
A1:800V systems can charge up to twice as fast as 400V systems, allowing you to add 200km of range in about 10 minutes.
Q2: Will 800V chargers work with all electric vehicles?
A2: Not all EVs are compatible with 800V charging. Most older models will continue to use 400V, but many new models are being built to take advantage of the faster charging technology.
Q3: Is battery swapping better than 800V charging?
A3: Both have their pros and cons. Battery swapping is faster but requires expensive infrastructure, while 800V charging is more scalable and compatible with a broader range of vehicles.
Q4: How does MOREDAY contribute to the 800V ecosystem?
A4: MOREDAY is developing 800V-compatible charging infrastructure, focusing on fast charging stations that are efficient and sustainable.
Q5: What’s the future of 800V technology?
A5: As charging infrastructure continues to evolve, 800V systems are expected to become the industry standard, offering faster charging and helping to alleviate range anxiety for EV drivers.
Derek Ke
Hi, I’m Derek Ke, founder of Moreday.com, an expert in solar-protected electrical products and electric vehicle charging.
Over the past 15 years, we have helped nearly 500 customers (such as farms, residential, industrial, and commercial) in 60 countries solve new energy and green power problems. We aim to share more knowledge about solar power generation and new energy with everyone so that green electricity can enter thousands of households.
