Industry Insight

How Long Do Electric Car Batteries Last? The lifespan of electric car batteries is a multifaceted subject influenced by various factors. Here’s a detailed and informative analysis, incorporating relevant figures and information to help you understand how long these batteries typically last. Overview The lifespan of an electric car battery is usually defined not by complete depletion but by the national standard where the battery capacity drops to a specific percentage (e.g. 70%) of its original capacity. Several factors influence the lifespan of EV car batteries, including charging and discharging frequency, depth of discharge, usage duration, environmental conditions, and thermal management. Specific Lifespan for Electric Car Batteries Usage Duration Cycle Life Shelf Life Influencing Factors Electric Car Batteries Maintenance Recommendations Summary The lifespan of these batteries is influenced by various factors. Generally, lithium batteries last between 8 and 10 years, with an effective lifespan of 5 to 7 years. Proper usage and maintenance can extend battery life. Additionally, with ongoing technological advancements, future electric car batteries are expected to have longer lifespans and improved performance. By understanding these factors and following best practices for maintenance, electric car owners can maximize the lifespan and efficiency of their vehicle’s batteries, ensuring reliable performance and cost-effectiveness over time. At Brogen, we provide customizable EV battery solutions. Inquiry: contact@brogenevsolution.com

What is an Electric Vehicle Traction Battery? An electric vehicle (EV) traction battery, commonly referred to as an EV battery, is a critical component essential for electric vehicles, electric trains, electric trucks, and other similar applications. It plays a pivotal role in the advancement of new energy vehicles, making a significant stride towards future energy transitions. Below is a comprehensive overview of electric vehicle traction batteries: Definition and Applications Electric vehicle traction batteries serve as energy storage solutions designed specifically to power electric vehicles, electric trains, electric trucks, and comparable electric applications. They distinguish themselves from traditional auxiliary batteries primarily used to ignite combustion engines in automobiles. Types of Electric Vehicle Traction Batteries These batteries encompass a variety of types, including: Structural Composition of an Electric Vehicle Traction Battery Typically, an EV traction battery comprises: Key Features The EV traction batteries offer the following distinct features: Applications These EV batteries find applications across several industries: Conclusion In conclusion, EV traction batteries stand as pivotal components within new energy vehicles, facilitating the transition to sustainable energy practices and environmental conservation. With ongoing technological innovations and expanding market horizons, the future prospects for EV traction batteries appear increasingly promising. At Brogen, we supply EV traction batteries for almost all types of electric vehicles and provide customizable OEM / ODM services. Learn more here: https://brogenevsolution.com/ev-battery/ Inquiry: contact@brogenevsolution.com

Everything You Need to Know About The On Board Charger for Electric Vehicles What is an on-board charger? An On Board Charger (OBC) is a device that converts AC power into DC power. It transforms the AC voltage from charging stations into the DC voltage required by the battery. OBCs are installed in electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs). They enable these vehicles to be charged using AC power from residential or public charging stations. The output power of an OBC typically ranges from 3.3 kW to 22 kW. A significant advantage of OBCs is their ability to charge electric vehicles using standard household outlets. What are the different methods of charging an electric vehicle? Electric vehicle charging stations can be broadly categorized into two types: AC charging stations and DC charging stations. AC Charging Stations As the name suggests, AC charging stations provide alternating current (AC) from the electrical grid to electric vehicles. The onboard charger then converts the AC to direct current (DC) to charge the vehicle’s battery. These stations, also known as Level 1 and Level 2 chargers, are used in residential and commercial applications. The advantage of AC charging stations is that the OBC can adjust the voltage and current according to the vehicle’s needs. This eliminates the need for the charging station to communicate with the electric vehicle. However, the disadvantage is their low output power. It results in longer charging times. AC power from the grid is delivered directly to the OBC via an Electric Vehicle Supply Equipment (EVSE), which then converts it to DC and charges the battery via the Battery Management System (BMS). DC Charging Stations DC chargers take AC power from the grid and convert it to DC, bypassing the OBC to charge the battery pack directly. These chargers typically deliver high voltages up to 600V and currents up to 400A. Unlike AC chargers, which take 8-16 hours to charge a vehicle, DC charging stations can fully charge an electric vehicle in approximately 30 minutes. These stations are also known as Level 3 chargers, with the chargers referred to as DC Fast Chargers (DCFC) or Superchargers. The main advantage of DC chargers is their fast charging time. However, they are technically complex and need to communicate with the electric vehicle to charge it efficiently and safely. As shown in the typical DC charging system diagram, the EVSE bypasses the OBC and delivers DC power directly to the battery pack. The standard capacity of a DC charging station ranges from 50 kW to 300 kW. It’s more than 6 times the capacity of a single-phase on-board charger. However, AC charging through the OBC has less impact on the battery and minimizes battery aging. What are the functions of the onboard charger? The primary function of the OBC is to manage the charging process from the power grid to the vehicle’s battery. The OBC is designed to charge the battery as quickly as possible while minimizing battery degradation. It offers two charging methods: constant current charging and constant voltage charging. Constant current charging: this method charges the battery faster, but cannot fully charge the vehicle. Constant voltage charging: also known as trickle charging, this method charges the battery more slowly but with greater control, allowing the vehicle to reach a full charge. To optimize charging speed, the OBC uses constant current charging at the beginning of the charge cycle and switches to constant voltage charging toward the end. The OBC also plays a critical role in the bi-directional charging mode available in some vehicles. This capability allows it to convert DC power from the high-voltage battery pack back to AC power, supporting AC loads (Vehicle to Load, V2L), grid power (Vehicle to Grid, V2G), and even home power (Vehicle to Home, V2H). Hardware architecture of the OBC The OBC primarily consists of the following hardware components: Input Voltage Measurement Circuit: Measures the input voltage to control the conversion circuit. Input Filter: Suppresses internal noise or noise from external devices. Full-Wave Rectification Circuit: Converts AC voltage to DC voltage. Power Factor Correction (PFC) Circuit: Improves power efficiency degraded by waveform phase shifts. Voltage Conversion Circuit: Converts voltage using components such as an isolation transformer and field-effect transistor (FET) switches. Output Filter: Suppresses noise generated internally. Output Voltage Measurement Circuit: Measures the output voltage to control the conversion circuit. Control Circuit: Manages the conversion circuit and other components. DC/DC Converter: Provides power to the control circuit. Communication Interface: Facilitates communication with external devices. What are the trends and challenges in OBC development? The OBC is a critical component for both battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs). As the number of electric vehicles increases, the number of vehicles equipped with OBCs will also increase. At the same time, more electric vehicles will be equipped with DC fast charging capabilities.Key trends and challenges in OBC development include: Adaptation to 800V High-Voltage Platforms: OBCs will be compatible with these high-voltage systems. Increased Output Power: As 800V platforms become more common and battery capacities grow, OBCs will need to provide higher output power. Future OBCs will need to feature high voltage (high withstand voltage), high current, low loss, high heat resistance, and compact size. Bidirectional Charging Capability: OBCs will need to support bidirectional charging, allowing the conversion of DC power from high-voltage battery packs into AC power to support external AC loads. Use of Discrete High-Voltage Components: These components will be widely used in OBCs to enhance performance. Increased Power Requirements: The trend towards fast charging will significantly increase the power requirements of OBC topologies. Our On Board Charger Systems Engineered for top-tier power conversion efficiency and remarkable power density, our chargers cover a broad power spectrum, ranging from 3.3 kW to 40 kW. Whether you’re driving a passenger car, bus, van, or LCV, or require upfit power supply for specialized vehicles, our comprehensive solutions ensure seamless integration and optimal performance.  Applicable for both PHEV and BEV Wide input range, 1 phase

Recently, various new energy vehicle companies have been vigorously promoting the charging speed of electric cars as one of their key selling points: 5 minutes of charging for 200 kilometers, 12 minutes for 500 kilometers. And among them, the 800V high-voltage platform is repeatedly mentioned. What is the 800V High Voltage Platform? 800V is a relatively broad term. It does not mean that the entire high-voltage electrical system of the vehicle can always reach 800V. Instead, it’s an average. The voltage range of the entire vehicle is within 550V to 950V, which can be called an 800V high-voltage platform. Currently, most new energy vehicles use a 400V platform, with the voltage range of the entire vehicle electrical system between 230V and 450V. The mainstream 800V high-voltage platforms currently available in the market mainly consist of three types: the first type is full-range 800V, where all of the vehicle’s electrical systems, such as motors, batteries, controllers, air conditioners, DCDC, etc., support 800V; the second type is key components supporting 800V, such as the electric drive system and battery supporting 800V, while other components such as the air conditioner still use 400V; the third type is only the battery supporting 800V fast charging, while other components remain at 400V. In fact, the 800V high-voltage platform concept wasn’t new in 2023. As early as 2019, Porsche introduced the first production model, the Taycan, with an 800V high voltage platform. However, due to its high price, the 800V platform was once almost a luxury car-only configuration. By 2023, many 800V high-voltage platform vehicles have flooded the market, intense competition has driven prices even lower, and more consumers are now considering whether a vehicle has an 800V platform as an important purchase consideration. What are the benefits of the 800V high-voltage platform? The reason why automakers choose to upgrade to the 800V high-voltage platform is twofold: on the one hand, it can significantly improve the charging and recharging speed, and on the other hand, because the 800V high-voltage platform can reduce energy loss compared to the 400V volt platform, it can indirectly improve the vehicle’s range. However, the energy loss advantage of the 800V high-voltage platform is not very significant. This is because currently the highest efficiency of motors on 400V platforms can already reach about 97 to 98%. The room for improvement with the 800V high voltage platform is quite limited. If the 400V platform is well optimized, the energy loss can still be reduced. That’s why most car manufacturers have not promoted this aspect very much. In terms of charging speed, the advantage of the 800V high-voltage platform becomes clear. Power = Voltage x Current (P = UI). To increase charging power, you either increase current or voltage. However, there aren’t many automakers currently choosing to increase charge power through high current schemes, Tesla being one of the few. The biggest drawback of high-current systems is heating. As the current increases, the heat generated by the entire system increases geometrically, leading to overheating of high-voltage harnesses and battery packs. From an energy consumption perspective, heating increases the energy dissipated in the system. From a safety perspective, battery pack overheating also increases safety risks. In comparison, most automakers currently choose to increase voltage to solve charging efficiency issues. By increasing the voltage to achieve the same charging power, not only does the charging speed increase, but the current is also reduced accordingly, reducing the heat generated by the harness and battery. It also allows the use of thinner wire harnesses. What are the challenges of the 800V high voltage platform? However, whether the 800V high voltage platform can be used for fast charging during the charging process depends not only on whether the vehicle itself supports 800V, but also on the cooperation of the charging stack. Currently, there are relatively few 800V chargers on the market. However, some models are equipped with on-board voltage boosting systems that increase the charging voltage to 800V during the charging process, ultimately achieving fast charging. Inquiry: contact@brogenevsolution.com