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The Spectre of High Voltage. Down with the Volts!

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In the domain of electric mobility, until now there existed no viable alternative to high-voltage traction systems. However, the nanoFlowcell low-voltage drive system enables a high-performance powertrain to operate at much lower voltages—thereby demonstrating that electric vehicles can be simultaneously powerful, cost-efficient, and safe.

While electric vehicles remain uncommon on roadways, they have become integral elements of virtually every automotive manufacturer's product portfolio. Regardless of design variations and distinctive brand characteristics, all contemporary electric vehicles share a fundamental similarity—their reliance on high-voltage traction systems.

Both vehicular and drivetrain electrical systems operate exclusively on high voltage (HV) or employ hybrid configurations combining high-voltage traction with low-voltage vehicle electrical networks. Consequently, electrified powertrains have established high-voltage and high-power electronics as standard components within modern automotive technology.

Expressed differently, electrical currents reaching 600 volts now circulate through the wiring harnesses of modern electric vehicles. This characteristic generates significant anxiety among many drivers, making electric cars a source of apprehension. Critical media reports — particularly those concerning Tesla Model S incidents — intensify scepticism toward an otherwise technologically advanced propulsion system.

Low-High-Voltage Diagram
Overview of nominal voltage in e-vehicle traction systems

Overview of nominal voltage in e-vehicle traction systems

The era when automotive enthusiasts could perform maintenance work in residential garages has concluded with the emergence of electric vehicles. While traditional engine maintenance might have resulted in minor burns from heated components, direct contact with currents up to 600 V — equivalent to 2.5 times domestic outlet voltage — presents life-threatening hazards. Therefore, high-voltage system maintenance remains exclusively within the domain of certified workshop specialists, trained in the risks of high-voltage automotive systems.

Repairs to high-voltage vehicles are exclusively handled by specialized workshops, as depicted in the image from Grundlagen Kfz-Hochvolttechnik, Krafthand Medien GmbH, 2014.

Safety Collaboration and High-Voltage Risk Management

Electric vehicles simultaneously resemble conventional automobiles while representing fundamentally different technological platforms. Training requirements extend beyond internal workshop personnel. Automotive manufacturers and suppliers collaborate with fire departments and emergency response services to create safety protocols addressing the unique risks of HV vehicles during accident scenarios.

However, HV safety considerations begin already during the manufacturing phase. To prevent severe accidents from escalating into catastrophic events, enhanced structural safety standards ensure comprehensive contact protection and arc-flash barriers, shielding HV systems within the vehicle. These increased safety measures, though necessary, inevitably increase manufacturing costs.

Engineering Complexity and Cost Factors

Integrating high-performance electric drives operating at hazardous voltage levels into existing architectures, while maintaining safety across all operating conditions — from routine operation to accident recovery — requires extensive structural modifications compared to conventional petrol or diesel vehicles.

Critical components, particularly specialised HV cables and conductors, undergo manual manufacturing and multiple inspections to prevent production defects with potentially fatal outcomes. Additionally, cables are often Kevlar-reinforced to maintain integrity during impacts.

Are electric cars expensive because their HV components require specialised protection to prevent electrical hazards? Yes — but not only for that reason. The lithium-ion battery pack remains the most expensive single component in EVs with practical range capability.

Additional production costs remain under discussion, but one principle stands: safety must never be compromised, even amid the socio-ecological drive toward electrification.

QUANTiNO 48VOLT
The QUANTiNO 48Volt, equipped with the nanoFlowcell low-voltage drive, accelerates from 0 to 100 km/h in under five seconds and achieves a top speed of 200 km/h.

QUANTiNO 48VOLT

With low-voltage systems operating at only 48 V instead of up to 600 V, manufacturers could eliminate many HV-specific safety precautions and their associated costs. When low-voltage technology is combined with nanoFlowcell®, overall vehicle costs can approach parity with internal combustion cars.

nanoFlowcell Holdings developed its low-voltage drive to directly address the barriers preventing the widespread adoption of HV electric vehicles — safety and cost.

The 48 V nanoFlowcell® low-voltage drive is compatible with existing LV electrical systems and suitable for both compact EVs and high-performance sports cars.Performance equals that of HV systems, yet it provides superior safety and efficiency, as power demand never requires exceeding 48 V — a voltage safe for human physiology (AC becomes dangerous above 50 V; DC above 120 V).

Engineering and System Design

During QUANTiNO pre-development, Nunzio La Vecchia’s engineering team defined the technical specifications for a nanoFlowcell-powered low-voltage vehicle, developing the control unit, HMI (human-machine interface), and the complete LV traction and electrical systems.

“With QUANTiNO, we have fundamentally reconceptualised the entire concept of electric propulsion,” explains Nunzio La Vecchia, CTO of the nanoFlowcell Group.
“Our experience in prototype development and expertise in power electronics and software enabled a holistic development approach. We created new LV components and an innovative wiring harness to optimise installation space, weight, and component placement. With QUANTiNO, powered by our proprietary low-voltage system, we became the first organisation to reach production readiness for a daily-use low-voltage EV — offering clear advantages in development, production, and operation.”

bi-ION® Electrolyte Energy Storage

A further hallmark of the nanoFlowcell® low-voltage drive is its use of bi-ION® electrolytes for energy storage. Unlike HV vehicles that rely on lithium-ion cell packs (where higher power demands mean larger, heavier, and more expensive batteries), the QUANTiNO faces no such limitations.

QUANTiNO nanoFlowcell engine
nanoFlowcell with low-voltage architecture in testing
QUANT FE doors open
Flexible configuration: The centre tunnel in the QUANT FE is home to the tank for the bi-ION electrolytes

The nanoFlowcell energy converter is compact — barely larger than a shoebox — while the bi-ION® electrolytes (energy carriers) are stored in standard tanks requiring no special safety measures, as they are non-explosive, non-flammable, and non-toxic.

The flow cell determines energy throughput (the faster the car drives, the more electrolyte flows through the cell), while tank volume dictates vehicle range. After use, the bi-ION® liquid is vaporised and released as environmentally neutral emissions, comparable to water vapour from hydrogen vehicles. Refilling is a simple, rapid process.

This design gives engineers and designers wide creative freedom to develop innovative and economical vehicle concepts.

For consumers, it means freedom from thermally unstable lithium-ion batteries, and access to a safe, low-maintenance, cost-efficient propulsion technology.

Lithium-ion high-voltage versus nanoFlowcell low-voltage
High-voltage (lithium-ion)
"Rigid" battery packaging
Cost-instensive HV components (HV BUS, plugs, contacts, semiconductors, lithium-ion battery, etc.)
Additional expenses for integrating HV protection measures into the vehicle's structure, such as full galvanization and insulation monitoring.
Thermal collapse of the high-power lithium-ion cells
Costs for HV training: safety provisions necessary
Inherent risks for passengers, first responders, and emergency personnel during accidents
Low-voltage (nanoFlowcell®)
Flexible nanoFlowcell packaging
More cost-efficient LV components, cost-effective nanoFlowcell system
Cost-effective system architecture based on 48 V traction and vehicle electrical systems
Non-toxic and harmless electrolytes
Regular training: no additional safety measures required
Structural system safety in the event of accidents