Feature: Automotive Design


Higher voltage programmable power supplies assist 800V electric vehicle development


charge times. However, when comparing an internal combustion engine (ICE) to battery-powered vehicles, ‘range anxiety’ is a common concern. This concern is expedited because the EV’s heating and cooling systems for passenger comfort require power from the battery, and the media has recently publicised how cold weather further reduces battery range and performance.


By Mohamad El Boubou, product marketing manager for Programmable Products, TDK-Lambda EMEA


E


lectric vehicle (EV) unit sales are expected to reach 17.07 million by 2028. This will, of course, result in a similar surge in demand for


components, subassemblies, and test capability. However, the purchase price, charge time, and availability of charging stations remain significant barriers to EV adoption. Automotive manufacturers are already working to extend EV ranges and reduce


22 October 2024 www.electronicsworld.co.uk


Recent battery innovations Battery manufacturers are heavily investing in research and development costs and performance improvements. Many advancements have come from cell chemistry or design changes, pack engineering, and manufacturing processes. Lithium-ion is currently the most


popular battery chemistry to use, but these often contain cobalt, a toxic metal that comes with significant financial, environmental, and social implications. However, there are efforts to develop cobalt-free batteries where the cathode is, instead, based on organic materials. Early research suggests that this material is not only cheaper, but it can also conduct electricity at similar rates. Researchers claim that the cobalt-free battery will have an equivalent storage


capacity and can be charged more quickly than cobalt batteries. OEMs are increasingly focused on the


potential of solid-state batteries. These batteries, which do not include a liquid electrolyte, can be lighter, safer, faster to recharge, and more energy-dense while still delivering ranges exceeding 600 miles (965 km). But there is another way to boost the


range and speed up the charging time of an EV, and that is to increase the working voltage of the battery.


Increasing battery voltage EVs today mainly use a 400V system, but manufacturers are redesigning their vehicles to operate on 800V. When the battery voltage falls within the 300V to 500V range, it is commonly referred to as having a 400V architecture. Batteries within the 600V to 900V range are said to have an 800V architecture. Several EV manufacturers are already


supplying cars with an 800V system. Upping the battery voltage is necessary because 50kW of power at 400V equates to 125A of current drawn. At 800V, this reduces the current to 62.5A. A lower current means fewer losses in the conductor, both in the cable harness and in the motors (I²R - current squared x resistance).


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50