Continental Develops ‘AllCharge’ Technology for Cable Based Charging Station

Leading German company, Continental has developed an ‘AllCharge’ charging system that will make it possible for EVs to use any type of charging station. With the implementation of the system, vehicles can use the maximum output rate, up to 800V and up to 350 kW at all types of charging station, whether they are single-phase AC, three-phase AC or high-speed DC. Possibly speeding up the time for charging by at least 12 times.

Using the technology, Continental aims to convert the electric powertrain itself into a charger. A conventional electric powertrain has an inverter and an electric motor to facilitate the switch from AC to DC power. As these components by their inherent nature can constantly switch between AC/DC at different voltages, it is already possible for them to function together as a charging system. Continental leveraged this capability and is now able to provide interoperability with different charging technologies through an onboard, vehicle-based solution. With an output rate of  up to 800 V and up to 350 kW, drivers now have access to 230 volts of AC power for onboard use if needed.

Commenting on the technology, Dr. Oliver Maiwald, Head of Technology & Innovation in the Powertrain Division at Continental said that often charging stations do not allow drivers to charge as fast as they would like and with the launch of Continental’s AllCharge powertrain, drivers now do not have to worry about finding the kind of charging station that would be suitable for their specific vehicle. Their vehicle would now have the technology to obtain charge from all sorts of vehicle charging stations including single-phase or three-phase AC to fast-charging high-speed DC systems. Maiwald added “the maximum benefit can be reached for urban AC charging stations, here a 12 times faster charging is possible.”

 AllCharge system – the universal solution for all types of cable-based charging

From the infrastructure perspective, single-phase and three-phase AC charging stations are cheaper to install and hence these are the most widespread type of charging stations. But using them is impractical for long trips as they need a relatively long charging time. High-speed DC stations which need more expensive technology are not very common. Another barrier is that many cars are not equipped for high-voltage DC charging.

Dr. Martin Brüll, who is a responsible expert for the new charging system said that a universal solution which could work with any type of charging station was the need of the hour. Using its technology, production experience and expertise in the field, Continental developed its AllCharge solution. Allcharge is an innovative system which is essentially a modified electric powertrain in which the electric motor and inverter (which switches between DC and AC power) have been specially designed adapted to handle the additional task of charging. The only additional component that is part of this system is a DC/DC converter, which is meant to ensure an optimally regulated power flow to the battery at all times.

Five minutes charging time gives up to 150 km of range 

The vehicle has a single cable connector, but there are two ways that the battery can be charged. In the case of AC current, the current goes from the charging station to the inverter through the electric motor, where it is transformed into DC current before being supplied to the battery. In the event that the charging station provides DC current, the current from the charging station goes directly through the inverter to the battery.

AllCharge is compatible with any type of charging station, and can operate at a rate of up to 800 V and a power from 150 kW today and even up to 350 kW for special premium applications.

Dr. Brill said “With 350 kW DC charging, five minutes charging time provides approximately 150 km of driving range – a good indication of our charging system’s true potential. No matter how quickly the infrastructure develops in future, a vehicle with AllCharge technology will always be able to make the most of the selected charging station’s capacity.” At the Continental Tech Show and IAA 2017, Continental hosted the first ever live demonstrations of the AllCharge system.