Post-800 V electric vehicles

Abstract

This thesis concentrates on the requirements and implications of post-800 V electric-vehicle (EV) architectures by providing first an independent analysis of the transition from 400 V to 800 V systems. Beginning with an overview of high-voltage powertrain fundamentals, the work systematically reviews the roles and interactions of the battery, inverter, motor, and on-board charger subsystems. A structured literature survey of academic and industry sources identifies the principal benefits of 800 V systems, such as, reduced current requirements, lighter cabling, higher charging power densities, and improved overall efficiency, and contrasts these with the increased insulation demands, component costs, and safety considerations inherent to higher voltages. Quantitative comparisons between representative 400 V and 800 V EV models are conducted, examining metrics such as peak charging rate, energy losses, thermal performance, and system-level mass. The results indicate that 800 V architectures can deliver up to 50 % faster charging and reduce electrical losses by approximately 15 %, while incurring an estimated 15–20 % increase in power-electronics cost and complexity. Based on these findings, the thesis discusses design strategies and technological pathways to mitigate technical and economic barriers and offers guidance for manufacturers and policymakers considering the adoption of post 800 V EV platforms. The conclusions underscore the potential of high-voltage architectures to accelerate EV performance and charging infrastructure development, while highlighting areas for further research in materials, safety standards, and cost optimization.