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ITT introducing next-gen ultra-fast DC charging system; tested 400A at 1000V

ITT, through its Cannon brand, will introduce a next-generation, ultra-fast DC charging solution that can significantly reduce electric vehicle charging time at eCarTec 2016 in Munich next week. ITT will debut the high-performance, cooled ultra-fast charging DC solution as well as an improved contact system for its global portfolio of AC charging solutions.

One of the main obstacles to widespread adoption of electric vehicles is lengthy charging times. Our new cooled ultra-fast DC charging system delivers the charge required for 60 miles/100km within 3 to 5 minutes—a charging speed that will help accelerate public adoption of electric vehicles.

—Gary Ashurst, vice president and general manager of the ITT Interconnect Solutions transportation and industrial business unit

The liquid-cooled connector and cable design enables ultra-fast EV charge cycles with tested amperages of 400A at 1000V. The high power density is facilitated by a dielectric cooling liquid that runs from the cable throughout the connector’s contact system. The solution has a weight optimized cable design and minimized cable diameter, delivering a highly flexible, ergonomic and easy-to-use solution.

The improved AC contact system features multiple enhancements over the previous generation. Precision-engineered canted coil spring power contacts allow for minimal mechanical stress of contact partners, minimal resistance of charge current and increased resistance to misalignment. The design changes lead to significantly minimized power losses during the charging process and an extended lifetime.

In accordance with all key regional standards—IEC, SAE and GB/T—ITT offers a comprehensive line of AC charging solutions for electric vehicles. Connectors are available with an amperage range from 16A to 80A, single- and triple-phase variants, with low contact resistance and a minimum of 10,000 mating cycles.

Comments

HarveyD

This is a breakthrough in ultra quick charge facilities.

Three (3) minutes per 100Km = 15 minutes per 500 Km and is closer to acceptable quick charge.

Net generation will certainly do even better?

clett

400 kW = 1,400 miles per hour charging.

HarveyD

A somewhat defiant charger, challenging many posters?

Now is the time to develop 1000 Volt battery packs + appropriate drive trains and 400 Amps cables and connectors.

Not impossible but will scare many?

Herman

I’ll round down the charge rate, and say that you can charge your 120kWh Tesla Model Q at 360kW, for, let’s say, “empty” to 60% SOC.

So since it’s DC there’s far less conversion loss in the on-board charging circuit. Still the battery will exhibit charging losses on the scale of at least 4-5% (probably a whole lot more but I don’t want to make Henrik mad).

At 4% of 360kW, that’s 14.4kW that needs to be rejected from the battery at a relatively low deltaT. What sort of thermal management trickery is used to accomplish this? We’re talking about 50,000 BTU/hr of heat removal with a max temperature for the battery coolant at… what, maybe 40deg C max, with an ambient air temperature that may be just as high on a 99% day?

This looks fun but I think it’ll be harder than it looks.

Engineer-Poet

I strongly suspect that any vehicle which can handle that much charging power will have its battery thermal management system integrated with the air conditioning.  Dumping 50k BTU/hr is a lot, but it's not extremely difficult either.

Herman

As long as it's OK to haul around an air conditioner capable of cooling a ~200m^2 house in Houston, I agree.

Engineer-Poet

Many are already hauling around a substantial fraction of that much capacity.

HarveyD

There are many different ways to handle extra/unwanted battery heat during ultra quick charge operations.

1) New enhanced batteries will create a lot less losses and heat. It is basically a design challenge.

2) Battery packs could easily be designed with more built in heat absorbers.

3) The on board A/C and/or Heat pump could be used to remove part of the extra heat generated.

4) External ventilation and/or liquid cooling (or both) could be applied during ultra quick charges.

One thing is sure, 400+ KW chargers will be around very soon.

gryf

The Porsche Mission E already has an 800 volt charging system that can charge its batteries to 80% capacity in 15 minutes for up to 249 miles of range. It uses a liquid cooled lithium ion battery. The cooling technology has been proven in the lemans winning 919 Hybrid race car.

HarveyD

Yes gryf, recharging for 400 Km in 15 minutes or at a rate of 27 Km/minute is getting closer to the 12 minutes ultra quick charging required for future extended range (600 Km) BEVs.

Something like 600 Km charge in 12 minutes or about 50 Km/minute will be reached by 2025 or so.

We may see charging facilities doing 40 Km/minute by 2020 or so.

Arnold

I doubt that consumers would be able to physically lift the umbilical owing to cable size and and insulationrequirements while at the same time the risk of malfunction or damage will make it an unacceptable risk in a public place.
enough to fry a person to ash in about 4 seconds.
Or melt a passenger vehicle in a half hour.
As it is DC there would be no wireless available . That leaves robot arm of some sort.
So while it seems a real possibility, there will be many new tools and infrastructure required before we see this.
Starting 2020 - 25 I'd like to think that were possible for in house bus and commercial M. / H.D.V. facilities.

HarveyD

Yes, lighter, lower resistance, better insulated cables and connectors will have to be developed. Automated boom like arms could do it without user interventions and for added safety. It would certainly be the case for eADVs.

It is not impossible to do!

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