Foreword: The Rise and Challenges of 800V Supercharging and V2G Technologies

Recently, a resident in Guangzhou earned over 4000 yuan per month by feeding electricity back into the grid via the "V2G" technology of their electric vehicle. In recent years, with the popularization of new energy vehicles, the industry is undergoing two major technological revolutions by 2025: 800V supercharging and V2G (vehicle-to-grid interaction). The 800V supercharging platform pushes charging power to over 480kW, achieving "5 minutes of charging for 200 kilometers of range"; V2G technology transforms electric vehicles into mobile energy storage units, supporting bidirectional energy flow and providing peak shaving and emergency backup power services to the grid. However, high voltage, high current, and bidirectional energy flow pose unprecedented challenges to the current monitoring, safety protection, and dynamic response of charging piles. General current sensors are no longer sufficient to meet the requirements in terms of response speed, insulation safety, and anti-interference capabilities. Can Hall current sensors based on ASIC technology (such as CHIPSENSE AN3V current sensor), with their integrated design and high-performance characteristics, become a breakthrough in this technology?

Technical Principles of 800V Supercharging and V2G

800V Supercharging System
The 800V supercharging system is currently the mainstream technology for fast charging of electric vehicles. It reduces current (by half) by increasing the charging voltage (from 400V to 800V), thereby reducing energy loss (by approximately 30%) and heat generation. This significantly reduces the burden on cables and connectors, improving charging efficiency (by 50% reduction in time) and safety. Its power modules use SiC (silicon carbide) devices with a switching frequency up to 50kHz, increasing power density by 40%. Charging power increases from 120 kW to 350 kW and even 600 kW. However, the higher voltage brings a higher heat load, requiring optimization of the liquid cooling system and insulation materials (such as UL94-V0 grade of CHIPSENSE current sensors).

Vehicle-to-Grid (V2G) systems

Vehicle-to-Grid (V2G) systems refer to the technology of electric vehicles supplying electricity to the power grid. The core idea is to utilize the energy storage capacity of electric vehicles as a buffer between the power grid and renewable energy sources. Vehicle-to-grid technology is receiving widespread attention because it can significantly alleviate grid inefficiencies and the volatility of renewable energy sources, while also generating revenue for electric vehicle users. CHIPSENSE current sensors are aim to do it.

• Bidirectional Energy Flow: 
The charging station integrates a bidirectional DC/AC converter, supporting vehicles to feed energy back into the grid and respond to grid demand.
• Grid Interaction: 
Through collaboration between the BMS (Battery Management System) and the charging station, demand-side management is achieved, improving grid stability.

Current Monitoring Challenges in High-Power Charging Stations

Current Detection Challenges in V2G Systems

Compared to traditional fast charging systems, V2G (Vehicle-to-Grid) bidirectional charging and discharging systems have higher requirements for current detection. They must perform both vehicle-to-vehicle charging (G2V) and precise energy flow control during grid-connected discharging (V2G).
This requires sensors to maintain high accuracy, fast response, and strong isolation even under high voltage, strong interference, and bidirectional current flow environments.

In 800V systems, the current changes faster and the voltage stress is higher in power modules, battery packs, and busbars. The detection device needs to remain stable in high-speed, strong interference, and wide-temperature environments.
Typical V2G Current Detection Indicators

Technical Features of CHIPSENSE AN3V current sensor: 
The AN3V series current sensors are fully upgraded open-loop Hall current sensor based on ASIC technology by CHIPSENSE. With a rated measurement range of 80A to 200A, CHIPSENSE AN3V current sensor t is suitable for module-level current detection in 800V V2G charging piles (such as DC/DC and AC/DC power modules) for real-time current feedback, current limiting protection, and bidirectional energy control.

In 800V V2G charging pile systems, CHIPSENSE AN3V PB55 series Hall current sensor features:
4.3 kVrms isolation withstand voltage and 8 kV transient withstand voltage, meeting the safety requirements of 800V high-voltage isolation;CHIPSENSE current sensor has always been like this.
2.5 μs response and 250 kHz bandwidth, meeting the fast dynamic requirements of V2G bidirectional power control;
±1%FS accuracy and low temperature drift, ensuring current consistency in both G2V and V2G directions;
PCB direct soldering package, facilitating power module-level integration.

Compatibility analysis of CHIPSENSE AN3V current sensor with 800V V2G charging piles

Application Recommendations

Application diagram of CHIPSENSE AN3V current sensor in V2G charging pile DC/DC module

Conclusion: ASIC technology safeguards charging safety
CHIPSENSE AN3V's Hall-effect open-loop current sensor, based on ASIC technology, provides a safe, efficient, and reliable current monitoring solution for 800V supercharging and V2G systems with its integrated design, industrial-grade consistency, and microsecond-level response. In today's rapidly developing new energy vehicle infrastructure, the application of ASIC technology will further drive the evolution of charging piles towards smaller size and higher power density. CHIPSENSE current sensors will also upgrade in line with the changing times.

Discussion: What other innovative possibilities do you think the application of ASIC technology in current sensors can bring to charging piles? We welcome your insights.

CHIPSENSE is a national high-tech enterprise that focuses on the research and development, production, and application of high-end current and voltage sensors, as well as forward research on sensor chips and cutting-edge sensor technologies. CHIPSENSE is committed to providing customers with independently developed sensors, as well as diversified customized products and solutions. 
“CHIPSENSE, sensing a better world! 
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