2022 Hyundai Ioniq 5 and Kia EV6 fast-charging - Lacey, WA Contact online >>
2022 Hyundai Ioniq 5 and Kia EV6 fast-charging - Lacey, WA
2022 Kia EV6 fast-charging
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The Kia EV6 joins other EVs from Hyundai and Genesis in a large recall.
The 2025 Lexus RZ EV costs between $43,975 and $58,605.
Porsche won''t go all-electric as quickly as planned.
VW sees little payback for adding multi-speed transmissions to EVs—and other ways to boost efficiency.
The Kia electric truck related to the EV9 SUV still isn''t a shoo-in for America—likely because of its potential price.
Kia ready with flexibility to favor EVs, hybrids, or plug-in hybrids—including future PHEVs with lots more electric range.
New electric-vehicle plant would be able to build up to 400,000 vehicles each year, when both phases are built.
It is an exciting time in the automotive industry with the development and evolution of new technologies for electric vehicles (EVs). Specifically, battery technology is the key driving force for innovation in the industry. Battery manufacturers must overcome the two major challenges to consumer adoption and growth of the market: total driving distance between charges and charge time.
Battery manufacturers are researching new battery chemistries to achieve greater capacity and charge at higher rates without an increase in battery size. They are also making batteries using the existing battery chemistries, primarily lithium-ion and lithium phosphate, with higher voltage and higher Ah capacity battery packs.
The dynamics of the market pose challenges for testing EV battery packs. Since the battery pack is the most expensive component of an EV representing between 20% to 40 % of the vehicle cost and due to the safety issues with lithium-based batteries, test engineers must 100% test all batteries.
Rising battery pack voltages and increasing battery power and capacity add to the challenges of a growing market and higher throughput requirements. Thus, test systems need to be adaptable to evolving higher voltage and higher capacity battery packs, new battery chemistries and greater throughput demands.
Today, lithium-ion is the most common EV battery chemistry. Lithium-ion batteries offer high energy density, but they have the risk of thermal runaway necessitating a cooling system for the battery pack to prevent a damaging overtemperature condition. Fully charged lithium-ion battery packs can provide a driving range of around 300 miles.
READ MORE: Navigating the Electric Mobility Path with Solid-State Batteries
Lithium-ion batteries made for the North American and European markets include either nickel, manganese and cobalt (NMC) or nickel, manganese, cobalt and aluminum (NMCA). Chinese battery manufacturers utilize lithium-iron-phosphate (LFP), which has a lower energy density than NMC- or NMCA-based lithium-ion batteries. Thus, a comparable capacity LFP battery must be larger than a nickel-manganese battery.
Several new battery technologies are under investigation. Some of the more promising new types include solid-state, lithium-sulfur, graphene and zinc-air batteries.
Solid-state batteries could double the range of EVs. Solid-state batteries have higher energy density than lithium-ion batteries and consume less space for an equivalent capacity battery. The electrolyte is a solid material such as a polymer, a ceramic or a glass. The anode can be graphite, silicon or lithium; the cathode can be a nickel-based material. Ions can move more quickly through the solid electrolyte allowing faster charging.
Without the highly reactive lithium electrolyte, the risk of thermal runaway is substantially reduced. The solid-state battery is a much safer battery and it requires a lower cost production process. Although still in the laboratory, Toyota is planning to have a solid-state battery in an EV by 2030.
Figure 1 illustrates the differences between a lithium-ion battery and a solid-state battery. The solid-state battery does not require a separator. As a result, it is smaller than the lithium-ion battery.
Researchers are investigating solid-state lithium-sulfur batteries that combine high energy density of lithium-sulfur with the safety and stability of solid electrolytes. In Europe, scientists believe that a lithium-sulfur battery has a lesser environmental impact than a Lithium-ion battery since cobalt is not a component of a lithium-sulfur battery. The most significant challenge to commercializing a lithium-sulfur battery is increasing its relatively short lifespan.
The nanotechnology material, graphene, is a single-atomic layer of carbon atoms that combines high charge carrier mobility, high thermal conductivity and high strength. Researchers are investigating a graphene-based battery for the EV market. Graphene batteries offer the benefits of a more rugged structure, lighter weight, and superior heat dissipation compared with lithium-ion batteries. Superior heat dissipation during discharging and charging reduces the risk of thermal runaway.
READ MORE:When Electric Vehicles Take Over
Graphene can also store larger amounts of energy per unit volume, and it can recharge at a higher rate. Unfortunately, challenges with graphene include scalable production, integration into existing battery manufacturing processes and cost-effectiveness. The emergence of a graphene battery will require some technological breakthroughs.
Zinc-air is another battery chemistry that is both inexpensive and capable of high power. The power derives from the oxidation of zinc. The oxidation process degrades battery performance over time. Commercialization of a zinc-air EV battery would require solving that problem.
Most likely, the automotive vehicle manufacturers will have several options for EV batteries. Each manufacturer will choose a battery technology or technologies that best suit the different types of vehicles that the manufacturer makes. Test systems will need to be adaptable to testing different battery types.
Higher battery voltage can make an EV more efficient and contribute to extended driving distance. For a given motor load, a higher battery voltage reduces the maximum current requirements. The vehicle can use smaller gauges and lighter cables. With less power lost in the cables and with less weight, vehicles can increase driving distance.
Many vehicle manufacturers have transitioned from 400 V to 800 V batteries to obtain the higher efficiency and lighter weight that a higher voltage offers. Larger electric vehicles such as trucks, trains and airplanes, could soon use even higher voltage batteries.
Constructing an 800 V battery requires a series combination of over 200 lithium-ion cells that generate a nominal voltage of 830 V. During regenerative breaking, the battery voltage can reach 860 V. Using a switching power supply for charging requires a circuit that operates 150 V to 200 V over the nominal battery voltage.
READ MORE: Lithium Forklift Batteries Find Second Life in Solar Energy Storage
Certainly, increased battery capacity can substantially increase driving distance. High performance vehicles incorporate 100 kWh to 135 kWh capacity. At least one manufacturer uses a 200 kWh battery in one of its vehicles. Some manufacturers are experimenting with battery capacities over 200 kWh. The battery packs used in high performance vehicles can deliver over 600 kW. Battery packs for heavy-duty commercial vehicles may need to deliver over 1 MW.
Growth projections for battery-specific energy over future time periods can be found here.
Higher Power and Faster Charging
Charging time compared with filling the tank of an internal combustion vehicle is a major barrier to EV adoption. High-power DC fast charging systems, categorized as Level 3 chargers, can deliver up to 350 kW and have the capability to add charge to a battery equivalent to as much as 200 miles in only 10 to 15 min.
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