In 2019, Porsche set a new benchmark in the automotive industry with the introduction of the Taycan, the first vehicle equipped with an 800V high-voltage platform. This groundbreaking technology not only supports an 800V DC fast charging system but also accommodates 270KW of high-power fast charging, significantly reducing charging times and enhancing driving range. The adoption of 800V technology by other major automakers like Volkswagen, Mercedes-Benz, and Audi underscores its importance and the transformative impact it is poised to have on the electric vehicle market.
Comprehensive System Upgrades for 800V Implementation
The integration of 800V technology necessitates substantial upgrades across multiple vehicle systems:
- Battery System: At the heart of the electric vehicle, the battery system consists of several components including modules, casings, control units, and specialized cooling systems tailored to manage the increased power and heat generated by 800V operations. Innovations such as JiKrypton’s gold brick battery demonstrate the capabilities of 800V technology with features like 500kW charging power and a 4.5C charge rate, which can extend the driving range by over 500km in just 15 minutes of charging. This rapid advancement is mirrored by Maga CATL’s 5C Kirin battery, which boasts a 500km range replenishment in just 12 minutes.
- Electric Drive System: This system encompasses the drive motor, motor controller, and motor reducer. Modern electric drive systems are characterized by high integration, focusing on maximizing power while minimizing consumption and physical footprint. For instance, the development of oil-cooled flat wire motors adapted for the 800V platform highlights efforts to achieve higher power density and efficiency.
- High-Voltage Wiring Harness System: The shift to 800V allows for a reduction in the electrical current, which facilitates the use of thinner wiring harnesses, thereby reducing weight and heat generation within the vehicle. However, the transition from the established 400V systems presents challenges, primarily due to the incompatibility of existing wire harnesses and connectors with higher voltages. Furthermore, for charging powers exceeding 200kW, the implementation of liquid-cooled cables becomes necessary, although their bulkiness and the lack of established protocols for their integration pose significant challenges.