EV Charging: Why 800-Volt EVs Could Be the New Standard
By doubling their voltage, new EVs should charge more quickly, require less wiring, and use smaller battery packs.
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A key factor in boosting the practicality and public acceptance of electric vehicles (EVs) is minimizing charging time. Making an EV easier and faster to electrically top up will likely mean more time spent on the road, versus parked at home- or public-charging stations.
A big bump in voltage architecture can make new EVs significantly faster to charge than in the earlier days, as well as allow for more simplified wiring and battery systems.
A Matter of Voltage
Most mass-market electric vehicles, including Tesla, have used a 400-volt electrical architecture to run their propulsion systems. That's a voltage standard established by early EV pioneers such as the Nissan Leaf, and it reflects the limitations of the charging stations of a decade ago.
The release of the Porsche Taycan in 2019 managed to up the game with its 800-volt system, which effectively doubled the vehicle's charging capacity, drastically cutting the amount of time needed for a get-back-on-the-road charge.
800-Volt (and Higher) Innovators on the Way
Following the example set by the Porsche Taycan — whose 800-volt system is similar to the one used in the Audi e-tron GT — other carmakers are shifting to 800-volt EVs, which may help simplify charging as public infrastructure ramps up to offer higher-voltage chargers and more charging spots for EVs.
Some other 800-volt models include the Hyundai Ioniq 5 and the Kia EV6, which boast the ability to go from a 10% to 80% charge in less than 20 minutes when plugged into a fast-charging 350-kW DC station. That's a drastic change from the long replenishment times of older EVs at charging stations, as well as the slow overnight charges required from wall sockets.
The higher-voltage standard is going to be adopted by General Motors for its future products, and companies including Toyota/Lexus, Rivian, Volvo/Polestar, and Stellantis' Ram/Dodge/Jeep are also slated to get 800-volt architecture. The standard will likely be more common by 2025 and beyond.
Luxury EV pioneer Lucid has gone even further with its Air EV, equipping it with a system over 900 volts, which helps the vehicle achieve its 512-mile range. Lucid's super-high-voltage allows for game-changing charges in 12 minutes that can add 200 miles.
Other Benefits Come With Higher Voltage
Higher voltage allows for lower operating current, which means that EVs can be built more efficiently, with slightly less industrial-strength electrical systems. Older 400-volt systems needed thicker wiring and more copper built into their electric motors in order to improve safety with handling the heat stresses of the charging process.
In addition to faster charging, the 800-volt architecture operates with less heat loss. Thinner wires, and fewer of them, cut down on the complexity and costs related to EV construction, and a higher-voltage system can also take advantage of smaller on-board battery packs, further cutting vehicle weight and reducing manufacturing costs and requirements.
Written by humans.
Edited by humans.
Andy StonehouseAndy Stonehouse literally fell into the world of auto writing while working as a ski-town journalist, and has not looked back since. A childhood spent dealing with the eccentricities of a 1976 MG Midget has made any subsequent auto experience a more safe and reliable drive. He has been blessed with nearby mountain trails and snowy roads in Colorado to do TV-adventure-styled test drives on a weekly basis.
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