‘AllCharge’ technology by Continental to enable cable based charging station

The leading German automotive manufacturing company unveiled ‘AllCharge’ charging system to make Evs fit for any type of charging station. The system can use use the maximum output rate, up to 800V and up to 350 kW at all types of charging station – single-phase AC, three-phase AC or high-speed DC with a benefit of 12 times faster charging.

 At the IAA Frankfurt Motor Show in September and at Continental Tech Show in June 2017 technology company Continental will be providing solutions to charging infrastructure for electric vehicles. It aims at converting the electric powertrain itself into a ‘charger’.

The  ‘AllCharge’ system technology is based on the components of a conventional electric powertrain (comprising electric motor and inverter – for switching between DC and AC power). Since constant AC/DC switching at different voltages is already an inherent feature of the electric powertrain, these components already possess all the necessary capabilities to function as a charging system. By exploiting these capabilities, Continental is now able to provide interoperability with different charging technologies using an onboard, vehicle-based solution. With an output rate of  up to 800 V and up to 350 kW, drivers also have 230 volts of AC power available for onboard use if needed. 

“Today, EV drivers often end up parking at a charging station that doesn’t allow them to charge as fast as they would like,” says Dr. Oliver Maiwald, Head of Technology & Innovation in the Powertrain Division at Continental. “With Continental’s AllCharge powertrain, drivers no longer need to worry about finding the right type of charging station. Their vehicle is equipped for every type of technology, from single-phase or three-phase AC to 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

 Efforts to expand the current infrastructure confront a recurring dilemma: single-phase and three-phase AC charging stations, which are cheaper to install and therefore the most widespread type of charging point, entail relatively long charging times, making them impractical for long trips, while high-speed DC charging stations, with their expensive technology, are still very few and far between. What’s more, many electric cars are not yet equipped for high-voltage DC charging.

“What was always lacking up until now was some sort of universal solution capable of working with any type of charging station,” says Dr. Martin Brüll, who is a responsible expert for the new charging system. “Such a universal solution is now available in the form of AllCharge.” Drawing on its expertise, technology and production experience, Continental has developed an innovative system which is basically a modified electric powertrain in which the electric motor and inverter (which switches between DC and AC power) have been specially adapted to handle the additional task of charging. The only extra component involved in this system is a DC/DC converter, whose job is 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 is equipped with a single cable connector, but there are two possible charging current paths to the battery. In the case of AC current, the current flows from the charging station via the electric motor to the inverter, where it is converted into DC current before being supplied to the battery. In the case of DC current, the current from the charging station flows directly through the inverter to the battery. AllCharge works 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 up to 350 kW for special premium applications. “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,” says Dr. Brüll. “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 will host the first ever live demonstrations of the AllCharge system.