Electric Vehicle Supercharging

Petalite’s patented SDC technology will become the 5th fundamental charging architecture to be introduced to the industry; a truly single stage isolated design with a lower part count, higher reliability, longer lifetime, wider temperature range, higher power factor and efficiency to isolated Bridge designs. 

 

This allows electric vehicles the potential to charge at up to 460kW (920V at 500A), to compare this to traditional charging methods in the industry please refer to the graph below:

Available Solutions


How We Compare

The comparison chart above shows that Petalite’s SDC charging technology will become the fastest for both the current industry and the next generation versions being proposed; the orange dotted line shows the point at which 15 minute charging will provide 250 miles of range. 15 minutes has become widely accepted in the industry as maximum time to which the average customer is willing to wait for their vehicle to be charged to enable mass adoption of EV’s, this is roughly comparable to a fossil fuel vehicle refuelling stop (including the detour, the queuing, the fuelling, the bathroom break and payment). 

 

However, Petalite’s SDC technology is only limited to 460kW due to the current generation of power connector available (1000V @ 500A) and can be expanded to much higher power due to the ability of the Petalite SDC charger being easily paralleled together. This can be seen in the electrification of commuter trains where power of 750kW to 4,500kW are to be required for fast charging; Petalite are currently developing this system in partnership with Train Manufacturer Vivarail and the UK Department for Transport.

 

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Key Hardware Advantages

• No High Voltage Aluminium Capacitors: Drastically Increases Reliability

• 4x Longer Lifetime: Estimated >600,000 hour life

• True Single Stage: No power factor correction stage required > 0.999 PF 

• Wider operating temperature range

• Smaller Bill of Materials: > 30% reduction in component costs 

• Low current ripple: <6% @ 300Hz (1.5% with next gen version)

• Flexible voltage ranges: 12V - 57.8V or 150V - 920V

• Isolated AC/DC Design: Efficiency to date 93% at 500V - > 95% at 920V

• Paralleled architecture: 750W – 5,000kW+

• Much lower lifetime cost: Less Downtime, Less Service

• Development path to meet CHAdeMO and CCS EV standards established


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Hardware Design


The Petalite SDC Supercharger has only one power stage on the High Voltage primary side. This battery charger is power factor corrected without the need of a Power Factor correction (PFC) pre-regulator stage. The AC current drawn from the mains is always in phase with the mains AC voltage, i.e. the power factor (cos φ) is always higher than 0,9.

A single staged battery charger means fewer components (no boost inductor, no high voltage electrolytic capacitors, no blocking diode, no PFC controller, no PFC power MOSFET) resulting to lower cost, higher reliability, higher efficiency, higher power density.


Market Comparison

Standardised Packaging

To enable long operating lifetime and ease of service, the Petalite SDC charger modules are packaged in a standard 39U Server dimensions, this enables economies of scale, reduction in packaging costs, and faster route to market. The first generation of SDC charger are housed in a 2U server rack design and each contain 6.5 kW of charging capability. Further revisions will aim to reduce cost and increase power density to match current market leaders in the market. 

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Safety

Petalite's technology allows the detection of the 'cause' by analysing cell resistance and impedance up to 100 times per second, significantly faster than existing methods. The technology also learns from other deployed chargers and the history of the battery in order to charge at optimal safety levels.

SDC Supercharging Features


Lower B.O.M costs

Petalite’s SDC Supercharging technology allows the use of simplified Flyback / SDC topology up to and beyond 1kW and no high voltage aluminium electrolytic capacitors.

Longer Life hardware

Silicon carbide mosfets and zero high voltage aluminium capacitors equals a higher mean time between failure compared to traditional charging topologies.

New PCB Architecture

The hybrid Flyback / SDC architecture can be integrated into any new / existing product development cycle.

Battery Asset Management

Petalite’s Asset management platform combines machine learning and condition monitoring to predict residual value in battery systems throughout large deployments.

Machine Learning

Advanced IOT integration and global connectivity enables the Petalite charging system to adapt to local environmental conditions and learn histories of other battery cells, improving safety and performance.

Ready to Intergrate

Petalite work with existing product design teams to incorporate the fast charging technology into your product within a minimum time frame and minimum cost for tooling.