Charging – what can be more simple?
SAE J1772 ™
Charging –What Can Be More Simple?
We charge our electronic devices everyday
–Laptops
–Cell phones
–PDAs
–Bluetooth devices
–Power tools
–MP3 players
–Toys
–Other…
Why the Confusion?
• Many factors determine a device’s battery size, capacity and recharge time
– Power requirement
– Duty cycle
– Physical size
– Target cost
• Each manufacturer is allowed to optimize a device’s battery strategy
• Results in abundance of solutions!
PEV Charging –A Different Road
• Minimize charging equipment based on use cases
– Residential slow charge rate –portablecord sets
– Residential and public intermediate charge rate –fixed charge equipment
– Public fast charge rate –fixed charge equipment
• Commonizethe user charging experience
– Gasoline pump analogy –Each pump may have multiple grades of gasoline available but
fueling is the same
– Reduces customer apprehension and speeds acceptance of the technology
• 120VPortable Vehicle Charge Cord
Terminology
• AC Level 1 Charging*
– 120V AC charging from standard 15 or 20 amp NEMA outlet, on-board
vehicle charger (~1.9kw)
• AC Level 2 Charging*
– 208 –240 AC charging up to 80 amps, on-board vehicle charger
(~19kw)
• DC Charging (Fast Charging)**
– Off-board charger connects directly to vehicle high voltage battery bus
– Charger controlled by vehicle which allows for extremely high power
transfer (>100kw) and thus faster recharge times (minutes instead of
hours)
– Actual charge rate limited by battery chemistry, infrastructure and
other factors
* Same charge coupler used for AC Level 1 and 2 charging** Requires unique charge coupler other than
the AC Level 1 and 2 coupler. Currently under development.
Terminology
• Electric Vehicle Supply Equipment (EVSE)
– General term used for any off-board equipment used
to supply charge energy to the vehicle. EVSE includes:
– Vehicle Charge Cord
– Charge Stands (public or residential)
– Attachment Plugs
– Power Outlets
– Vehicle Connector
– Miscellaneous Infrastructure
Components of PEV Charging System
–Vehicle Inlet/Plug
• 2 power contacts –up to 80 amps, 240V AC, 19.2kw
• 1 ground contact
• Control Pilot signal
– Verification of vehicle connection
– Supply equipment ready to supply energy
– PEV ready to accept energy
– Ventilation requirements
– Supply equipment current capacity
– Equipment ground present
• Proximity detection
– Indicates to vehicle that plug is present to prevent drive away
• Latch feature
Components of PEV Charging System –
Electric Vehicle Supply Equipment (EVSE)
• Can be a cord set or fixed mounted
• Includes enclosure and method of attachment
to AC mains (plug or direct connect)
• Generates Control Pilot signal
• Protects from ground faults
• Switches power to vehiclebased on vehicle
command
• Displays presence of AC input pow
Components of PEV Charging System
–On-Board Charging System
• Control system
– Interprets Control Pilot and proximity signal information
– Charge algorithm
• On-board charger
– Converts AC mains power to DC high voltage to charge PEV
battery
– Converts AC mains power to DC low voltage to power
vehicle system during charge
• Thermal system
– Condition PEV battery
– Cool charger
• Charge status indicator
PEV Charging –How It Works
• Charge plug not powered until plugged into
and commanded by vehicle
• Supply equipment signals presence of AC
input power
• Vehicle detects plug via proximity circuit
(prevents drive away while connected)
PEV Charging –How It Works
• Control Pilot functions begin
– Supply equipment detects PEV
– Supply equipment indicates to PEV readiness to supply
energy
– PEV ventilation requirements are determined
– Supply equipment current capacity provided to PEV
– PEV commands energy flow
– PEV and supply equipment continuously monitor
continuity of safety ground
• Charge continues as determined by PEV
• Charge may be interrupted by disconnecting the plug
from the vehicle
PEV Charging –Safety & Durability
• Receptacle and cord plug
– Specified to comply with international standards
including:
• J1772™
• IEC 62196
• UL 2251
• Electrical safety
– 10,000 cycle life with exposure to dust, salt and water
– Vehicle drive over does not expose a hazard
– Sealing
– Corrosion resistance
– Touch temperature limits
PEV Charging –Safety & Durability
• Supply equipment
– Specified to comply with international standards
including:
– J1772™
– IEC 61851
– National Electric Code, Article 625
– UL 2202, 2231
– Electrical safety (shock protection)
– Enclosure durability
– Charge cable durability
Summary
• Common interface standard
– No Beta vs. VHS confusion or apprehension
– Reduces overall cost to consumer
• Major components of charging system
– Supply equipment
– Portable vehicle charge cord
– Fixed charge stations
– Public charge stations
– Common interface plug and receptacle
– On-board charging system
– Charger
– Battery
– Charging controls
Summary
• Durability and safety
– Designed for 10,000 charge cycles
– Able to withstand vehicle drive-over
– Durable cabling
– Multiple layers of safety
– Ground Fault Circuit Interrupter
– Safety ground verification
– Finger-proof
– Sealed
– Vehicle control of charge power
– UL listed
