Electric vehicle charging inlet

Enabling High-Power Charging with Advanced Thermal Modeling

The evolution towards next-generation mobility will have a profound effect on vehicle architectures. Learn more, download our white paper today.

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Next-generation mobility will be defined by safer, more sustainable and convenient ways of moving around. Our vision is to co-create engineering solutions for the vehicle architecture physical and wireless connectivity challenges that will be key enablers of this vision.

IMAGINE CHARGING YOUR ELECTRIC VEHICLE IN JUST 10 MIN

For the design of next-generation electric powertrains not only the efficiency of the electric systems but also range, fuel consumption, and credible charging times will be primary considerations. In this domain, one key area of innovation is thermal management – enabling lighter and less bulky component design that can support high-power charging.

The aim for high-power charging is to charge a 300 km range in less than 10 minutes, however this would mean related thermal loads would be far higher than found in any normal electric vehicle operation.

350kW

Long distance in EVs will be enabled by fast charging with DC and a charging power of 350kW classified as High Power DC Charging (HPC DC).

10min

The aim of HPC is to compress a 300 km range into 10min charging time.

300km

With a charging power of 350 kW, it would be possible to gain up to 300km of additional range within up to minutes maximum.

CONNECTIVITY FOR HIGH-POWER CHARGING

Traditionally, regulators determined power ratings of terminal and connector designs from derating modelling, measuring current loads over time to test the limitations of relay and fuse technology. Ostensibly these models attempted to simulate current load peaks and their time duration. However, they were based on discrete root mean square (RMS) profiles, which simulated static conditions that seldom exist in real-life applications.

 

This practice has led to design overengineering. Combined with additional built-in safety margin to cover aging factors, this has created overly robust designs with excessive size, weights, and costs.

The aim of high-power charging is to compress a 300 km range into 10 min charging time, but the acceleration factor 16x in time is equivalent to a multiplication of the heat dissipation by 256x.

 

We are driving a new approach to achieve a realistic wire and component dimensioning for the industry’s required charging performance. This involves creating a link between thermal and electrical models and analyzing the relationship of the current profile to the temperature profile in any electrical powertrain wiring.