We outline the obstacles to rapid electric vehicle charging in the U.S., covering issues related to batteries, charging connectors, and more.
China’s electric carmakers are
outclassing their Western competition
So much so that it’s nearly ceased being surprising. However, their technological dominance reached such a peak recently that even those who aren’t automotive enthusiasts couldn’t help but take notice.
BYD, China’s top producer of electric vehicles, revealed something one might refer to as the
holiest grail of electric vehicle tech
A vehicle capable of charging almost as rapidly as you would fill up with gasoline.
Hefty
tariffs on Chinese automobiles
Implies that fast-charging BYD vehicles won’t be available in America shortly, which led us to wonder: What would it require for such technological advancements to reach the U.S.? Indeed, electric vehicle owners would appreciate charge points faster than today’s typical duration of 15 to 40 minutes.
The BYD Han L, as shown here, along with the Tang L, introduce the carmaker’s latest Super e-Platform and megawatt charging technology.
The primary elements involved are the vehicles and the requisite charging stations. We should examine what needs to occur within these sectors to facilitate the widespread adoption of ultra-fast, high-power charging across the U.S.
BYD’s Big Charging News
What BYD showcased primarily revolved around advancements in vehicle technology rather than introducing a more potent type of electric vehicle charger. Therefore, should other car manufacturers aim to achieve similar capabilities, they would have to fundamentally redesign their vehicles entirely.
BYD’s new
“Super e-Platform”
debuts in the Han L sedan and Tang L SUV, which
became available for purchase this week
. Its most eye-popping claim is that it enables 400 kilometers (250 miles) of range to be added in just five minutes of charging. Even if we shrink that figure to account for the generosity of China’s EV range estimates—under
more realistic EPA testing
, we’re discussing approximately 165 miles—which still outperforms the competitors.
Tesla says its
new Model Y
can add 169 miles of range in 15 minutes of charging. So the BYD notches charging times that are about three times quicker. The kicker: The Han L costs about the same as the Model Y in China.
The Cars
What sets BYD apart? It all begins with the heart of an electric vehicle—the battery. BYD has achieved advancements that other manufacturers would have to follow suit to match in terms of performance capabilities.
If you try to force an excessive amount of power into a battery cell not designed for it, you’ll encounter severe consequences, explained Bryan McCloskey, a chemical engineering professor with expertise in batteries at the University of California, Berkeley.
If the lithium ions in a cell move too quickly from a battery’s positive electrode to its negative one—that’s the process of charging—metal deposits can build up over time in a process called lithium plating. Too-fast charging can also create excess heat. Both outcomes can spur unwanted reactions within a cell, degrade its energy capacity over time and, in the worst case, lead to catastrophic failure.
However, with its newest “Blade” battery, BYD claims to have reduced the internal resistance within its cells, enabling ions to move more easily. It also appears they’ve successfully addressed the heating problem both at the individual cell and overall pack levels.
“I believe there’s absolutely no doubt that this is a groundbreaking achievement,” McCloskey stated, noting that the five-minute recharge showcased by BYD, which boosted the Han L’s battery level by approximately 60%, is “highly remarkable.” Nonetheless, he expressed interest in observing how durable these batteries prove to be after numerous cycles of charging and whether any significant issues arise over time.
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An additional crucial point: Typically, you can create a battery with high-energy storage or one that charges extremely quickly, but achieving both simultaneously is difficult. Therefore, the lithium-iron-phosphate cells created by BYD likely cannot store as much energy or provide the same level of range as those made by competitors. This partly accounts for why the Han L model has an EPA estimated range below 300 miles, which is adequate yet somewhat lacking.
BYD required an electrical system capable of managing the immense power output of its battery. Hence, the Super e-Platform has been designed with specifications including 1,000 kilowatts, 1,000 volts, and 1,000 amps.
In EVs,
Higher kilowatts mean quicker charging.
The Model Y is capable of supporting a maximum charging power of 250 kW.
Lucid Gravity
, now the quickest-charging EV in America, can
suck in an impressive 400 kW
BYD has manufactured the initial electric vehicle for passengers that can accept up to 1,000 kW, also referred to as one megawatt.
The 1,000-volt electric system plays a crucial role in increasing those kilowatts, which BYD claims as an innovation. According to the principles of physics, using a high voltage allows for greater charging power with minimal increases in current—or amperage—keeping overheating under control. Overheating is known to hinder rapid charging efforts. By optimizing this aspect, they aim to significantly enhance charging times without compromising safety due to excessive warmth generation.
Why then don’t all automobile manufacturers produce 1,000-volt electric vehicles? While they are gradually heading towards this and aiming for quicker public charging options, it’s not an effortless process.
Vehicles like the
Hyundai Ioniq 5
,
Porsche Macan Electric
and
Tesla Cybertruck
feature 800-volt electrical systems. The Gravity elevates this further with a 926-volt architecture. However, 400-volt systems have been the norm in the automotive industry for many years. Many of these parts are accessible to car manufacturers.
are intended for use with 400-volt systems
, and developing new systems raises expenses related to production.
To grasp why this advancement in vehicle technology occurred in China rather than the U.S., it’s important to acknowledge how much more progressed China’s electric vehicle market is in nearly all aspects. The Chinese government has played a significant role in this development.
invested trillions of dollars
To transform its automotive sector into a global leader. Additionally, China has faced significant consumer appetite and fierce rivalry among electric vehicle makers. As a result, BYD and its competitors have strong motivation to produce groundbreaking innovations to maintain their edge.
“Much of this innovation is driven by frequent announcements, typically every six or seven weeks, from companies like Huawei, Zeekr, or Xpeng,” explained Tu Le, managing director at the consultancy firm Sino Auto Insights, citing some of China’s leading electric vehicle manufacturers as examples. “In North America, who is challenging Tesla?”
The Charging
Currently, vehicles pose one limitation for implementing megawatt charging in America. However, we would also require new, high-power electric vehicle charging stations akin to those introduced by BYD with the Super e-Platform.
The car manufacturer unveiled a 1,360-kilowatt charger and announced plans to install 4,000 units throughout China. This device features two cords that users can connect to either the Han L or Tang L models’ twin charging outlets for optimal recharge speed. Additionally, BYD states that owners can use two regular chargers at once to double the electrical flow.
Most
DC fast chargers
In the U.S., ratings range from 150-350 kW. However, charging industry executives shared their insights.
InsideEVs
There isn’t much hindering megawatt chargers in the U.S., aside from insufficient demand.
On the infrastructure front, we can achieve that,
said Andrew Cornelia
The CEO of Mercedes-Benz High-Power Charging, overseeing sites with 400-kW connectors at their stations.
Firms such as Tesla are currently engaged in the development of megawatt chargers designed specifically for heavy-duty electric trucks. These vehicles feature large batteries that require highly powerful charging solutions to minimize downtime. Kempower, a company specializing in charging equipment, is also contributing to this effort.
1.2-MW charging unit
for electric semis.
High-powered charging is currently being developed in the U.S. for electric vehicles such as the Tesla Semi.
“We have never aimed at charging an electric vehicle in just 10 minutes,” stated Jed Routh, the vice president of markets and products for North America at Kempower. “It’s certainly not out of reach; however, it would require the vehicles being capable of handling such fast charging.”
Setting up megawatt charging stations might necessitate costly and lengthy power grid enhancements in some regions. This is already the case.
hindering the implementation of charging stations for electric trucks in California
BYD stated that big stationary batteries, often referred to as microgrids, could support the power grid at certain sites.
CarNewsChina
.
Therefore, five-minute, mega-watt charging is feasible in the U.S. However, is this capability really needed? Certain specialists and leaders within the electric vehicle industry question its necessity.
aren’t convinced
Cornelia referred to BYD’s declaration as a “turning point,” however, he mentioned that most refueling stops typically last between 10 and 12 minutes.
“That’s essentially the figure we’re aiming to determine,” he stated. “Is it necessary to charge within five minutes? Probably not.”
Moreover, BYD’s statement created quite a stir in America, a market where they do not actually sell vehicles. It seems rather unbelievable that other automotive companies wouldn’t envy such publicity—particularly in a region where automobile purchasers are motivated by desire rather than necessity.
Have information regarding electric vehicles or the charging ecosystem? Reach out to the author:
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