Combined Charging: The Universal Charging System

Combined Charging
the universal charging system
Robert Weber, BMW

Matthias Kübel, Volkswagen
Heiko Dörr, Coordination Office
Current Status Charging Systems
The main regions for e-Mobility have developed individual charging systems.
One global solution needed.
1st Step: start of e-Mobility with AC and DC 2nd Step: after migration
Combined Charging System for

Regional, mutually incompatible connectors
global AC and DC charging
Geschäftsstelle Ladeschnittstelle
c/o Carmeq GmbH
Combined Charging Survey, V1.3 2

Costumer Expectations drive Charging Capabilities
All DC fast-charging should be designed to meet customer needs and
wants.
ICE vehicles have a wide operating range

Operating range of current Battery EVs is
Long range
comparably limited before refueling
travels
Consumers expect convenient vehicle
fueling/charging
Many consumers don’t have access at home to a

Power access
convenient place to charge a plug-in EV.
at multifamily
homes Consumers still need a place to charge at/near
home
Battery driving range is sufficient for the vast

Emergency majority of everyday trips
charging Uncertainty of range limits to be overcome by fast
charging spots
c/o Carmeq GmbH

Design Requirements for the Combined Charging System
AC national standards remain the same.
Two additional Pins allow DC charging in the same vehicle inlet while accepting
the legacy AC connector.
up to
8h
Type 2 Type 1
Core Core
High High
Power Power
DC DC
How to speed up from up to 8 h charging to 20 min?
20 min
c/o Carmeq GmbH

How the Combined Charging System Responds
AC national standards remain the same.
Two additional Pins allow DC charging in the same vehicle inlet while accepting
the legacy AC connector.
up to
8h
Type 2 Type 1
Core Core
High High
Power Power
DC DC
20 min
c/o Carmeq GmbH

Design DC Combo 2 Inlet
The Combo 2 inlet provides comprehensive functionality
at a high level of safety.
Safety features Function

1 1
Diagnosable lock 1-phase AC charging with Type 2
2 2
Proximity and control pilot Integration into smart grid
3
3-phase AC charging with Type 2
4
High power DC charging via
dedicated pins
c/o Carmeq GmbH

Charging Connectors for the Combined Charging System
The Combo inlet shall serve as a universal plug for all relevant charging
scenarios.
DC-high
Household
socket
AC-1ph AC-3ph
c/o Carmeq GmbH

Combined Charging Connector Concept
The Combined Charging System integrates the existing AC connectors,
allowing for one standard global vehicle interface for AC and DC charging.
Connector Application range
USA Europe 5 kW 50 kW 100 kW

kW
AC 3,7
AC 10
AC 22
DC 86
c/o Carmeq GmbH

Comparison Combo 2 and alternative Approaches
Integration of AC and DC into a single inlet provides high freedom for vehicle
design and in addition a reduction of size.
Combo 2 CHAdeMO + Type 2
22 + x
54
32
x
102
70
74
Scale 2:3 Scale 2:3
c/o Carmeq GmbH

Impact on Vehicle Costs – Combined System vs Separate Systems
Separation of AC and DC charging systems has significant extra costs.
Total cost for customer is reduced by application of Combined Charging System.
Combined Charging System CHAdeMO with separate charging systems

Integrated electric architecture which implements all No integrated architecture for both AC and DC charging
relevant AC and DC charging scenarios Separate AC and DC connectors with two inlets in the
Integration of AC and DC in one single inlet vehicle
AC plus DC Charging DC Charging AC Charging
Consequences of a second separated charging system:

Module costs much higher than 50€ according to expert
evaluation*
Loss of installation space and freedom of design
through additional inlet
*depends on implementation
c/o Carmeq GmbH

Efficiency of Combined Charging
Integration of AC and DC in the vehicle architecture may be applied to charging
stations accordingly.
Connector Electric Vehicle
Type 1 Type 2
AC 1ph Type 1 CP
L N
CP PP Control Unit
N PE L1 Inlet with PWM
PP
PE
CP PP
and PLC
N
AC 3ph CP PP Type 2
N PE L1 Inlet L1/ L
L3 L2 AC-Charging
L2 Unit
(1- or 3- phase)
L3
Combo 1 PE
DC high Inlet
CP PP
PE
PP CP
PE
DC - HV Supply
- System
+ + - DC +
Combo 2
with
Inlet Battery
DC-Relay
c/o Carmeq GmbH
Design of charging stations, V3.0 11

Combined Charging System
Low Complexity and Cost Optimized:
Cost efficient re-use of multiple parts, resulting in win – win situation.
Electric Vehicle
Lock
PE
Charge
Control
Communication
Battery
DC
System
One inlet
No extra design required
Benefits
DC re-uses the complete AC communication and adds only DC specific data
Extensive use of same parts
c/o Carmeq GmbH

Design Combo Inlet
Easy Handling and Widely Spread User Acceptance: Single car design concept
that enables fuel tank as well as combined AC/ DC charging inlet.
The combo inlet fits behind typical fuel doors

No need for variants
c/o Carmeq GmbH

Video Demonstration
c/o Carmeq GmbH
Combined Charging, Key Challenges of e-Mobility V0.4 14

Simplified Architecture
To focus on the relevant components for high power DC charging
c/o Carmeq GmbH
Design of Charging System, V3.0 15

High Power DC Charging
Pilot enters state B instantly (very fast hardware based communication).
Vehicle immobilized.
c/o Carmeq GmbH

Close lock. Establish PLC communication: Exchange operating limits and
parameters of charging. In the end, pilot enters state C.
c/o Carmeq GmbH

EVSE performs isolation monitor self test and then initial internal isolation check.
EV performs initial internal isolation check.
c/o Carmeq GmbH

EVSE enables high power DC output. EV requests voltage to synchronize with
battery level. Voltage plausibility check is performed. EV closes DC relays.
c/o Carmeq GmbH

EVSE transfers energy per EV request.
Continuous monitoring of lock, isolation, voltage and temperature.
c/o Carmeq GmbH

Per EV request and pilot state B, EVSE regulates current close to zero and voltage
close to UBat (descending rate of 100 A/s).
c/o Carmeq GmbH

EV and EVSE open relays. EVSE disables high power DC supply. Any monitoring
will be stopped. Lock is disabled. PLC communication is terminated.
c/o Carmeq GmbH

Mobilize vehicle.
c/o Carmeq GmbH

Charging Communication for DC Charging
The charging communication between vehicle and charger is standardized in
ISO/IEC 15118 in close cooperation with SAE.
AC DC
charger battery battery
Charging control requires a permanent communication between vehicle and charge

Tasks pump.
Current and voltage are adjusted continuously during charging
One communication system for all charging modes, world-wide:

Requirements and functionality
Goal
Transmission technology
SW protocols
PLC-based communication ISO/IEC 15118 for all charging modes applying

Solution
IEEE 1901 HomePlug Greenphy, IPV6 and data security
c/o Carmeq GmbH

One Charging Communication for all Charging Modes
The Charging Communication shall realize intelligent charging with high
comfort by one implementation for both AC and DC charging.
Support of controlled intelligent charging based on dynamic rates

Controlled Forecast of network load through planned charging
charging Support of fleet- and load-management
Active control of network load
AC and DC Authentication with the same methods for AC and DC Charging

charging DC Charging takes control over voltage and status information
control Same communication technology for AC and DC Charging
Certified payment and accounting system

Value added
Future integration of vehicles in home networks or cloud services
services
Integration of Electric Vehicles into Smart Grid
Simple Using existing connections

realisation One implementation for all charging modes
c/o Carmeq GmbH

Charging Protocol defined by ISO/ IEC 15118
DC Charging communication is standardized based on existing AC Charging
communication.
DC Charging and AC Charging use the same Smart Charge

SLAAC (Stateless Optional: DHCP
Layer 7 – Protocol
protocol stack Application (Application Layer
Address (Dyn. Host
Autoconfiguration) Conf. Protocol)
+ Session Layer)
IPv6 based protocol
Transport layer with dedicated security Layer 6 –
EXI – Efficient XML interchange
Presentation
measured
Flexible XML-based messages Layer 5 – V2GTP (Vehicle to Grid Optional: HTTP (Hypertext
AC as well as DC messages Session Transfer Protocol) Transfer Protocol)
TLS (Transport Layer

Layer 4 – Security 1.0) UDP
Transport (User Datagram Protocol)
TCP (Transmission
ISO/IEC15118-3 focus on HomePlug Control Protocol)
GreenPhy as Layer 1 & Layer 2 solution
Layer 3 –
IPv6 (Internet Protocol)
Network
HomePlug GreenPhy on Control Pilot
Uses GreenPhy SLAAC for EV/EVSE Layer 2 –
Data Link
Association IEEE1901
HomePlug
Common Layer1 / Layer2 solution for AC and GreenPHY
DC-Charging Layer 1 –
Physical
c/o Carmeq GmbH

Station for (Semi-)Public Infrastructure in Europe
Minimal infrastructure should be realized with a dedicated charging station.
No specific equipment requirements for semi-public or private areas.
Strategic Impact
DC charging station without
discrimination of AC charging as
required by ACEA
Backward compaible design of
public infrastructure
c/o Carmeq GmbH
Design of charging stations, V3.0 27

Relevant International Standards for the Charging Interface
The charging system is comprised by a set of related standards.
4
Charging topology
2
Communication
1
Connector
IEC 62196-1 IEC 62196-3

IEC 62196-2 3
SAE J1772
ISO/IEC 15118 IEC 61850 Safety
SAE J2847 SAE J2931 IEC 60529

IEC 60364-7-722
IEC 61851-24 ISO 6469-3
IEC 61851-1 IEC 61851-23
SAE J1766
IEC 61851-21 IEC 61851-22 ISO 17409
c/o Carmeq GmbH

Standardization
Standards for DC charging are ready and implementation baseline defined.
DC systems according to Combined Charging Systems will be created according to

existing standards:
Connector: IEC 62196-3 CDV
Scope
Topology: IEC 61851-23 CDV
Communication: DIN Spec 70121
DIN SPEC 70121 refers to ISO / IEC 15118-1 DIS, -2 DIS and 15118-3
Series production of DC-Charging ongoing, Transparent requirements for all

products on the market
Benefits
Common agreement by all stakeholders
Standards aligned with SAE
Series products available End of 2012

Implemen-
Vehicles on the market in 2013 with DC option will comply to implementation
tation
Baseline baseline 2012 defined by IEC CDV 62196-3, IEC CDV 61851-23 and DIN SPEC
70121
c/o Carmeq GmbH

Summary of using DC Charging in Modellregion Munich
Final project presentation.
Impressions Facts
17.10.2011 in Munich
Ca. 100 guests
stakeholder from industry and
government
national press, customers
LIVE CHARGING
DEMONSTRATION
DC-Type 2 with PLC
with 70A (up to 28kW)
85km e-range in 30min
Press echo:
c/o Carmeq GmbH

Electric Cars with Combo Inlet.
Announced cars for 2013.
GM BMW Volkswagen
Chevy Spark I3 e-up!
c/o Carmeq GmbH

Strategic Assessment of existing Charging Systems
Main bodies have adopted the Combined Charging System as charging
technology.
All members of
the European
Association of
Automotive
SAE has developed the Combined
Manufacturers
Charging System in the U.S.
ACEA support the
The Combined Charging System is the
Combined Charging
US solution for electric vehicle charging –
System for Europe:
from AC charging to ultra-fast DC
charging.
BMW, DAF, Daimler, Fiat, Ford of
Europe, General Motors Europe, Hyundai
Nearly all global automotive companies
Motor Europe, Jaguar Land Rover, MAN,
support the Combined Charging System
Porsche, PSA, Renault, Scania, Toyota
including US manufactures Chrysler
Motor Europe, Volkswagen, Volvo Cars,
Group LLC, Ford Motor Company, and
and AB Volvo.
General Motors.
c/o Carmeq GmbH

Combined Charging System
Combined Charging: the universal charging system for electric vehicles has
been demonstrated with vehicles of German OEMs at the 15th international
conference „Electronics in Vehicles“ at Baden-Baden on October 12-13, 2011.
c/o Carmeq GmbH

Combined Charging System at EVS 26
c/o Carmeq GmbH

Combined Charging System at eCarTec
c/o Carmeq GmbH

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Combined Charging

the universal charging system

Robert Weber, BMW

Combined Charging System for

Combined Charging Survey, V1.3 2

ICE vehicles have a wide operating range

Many consumers don’t have access at home to a

Battery driving range is sufficient for the vast

Combined Charging Survey, V1.3 3

Combined Charging Survey, V1.3 4

Combined Charging Survey, V1.3 5

Safety features Function

Combined Charging Survey, V1.3 6

Combined Charging Survey, V1.3 7

Connector Application range

USA Europe 5 kW 50 kW 100 kW

Combined Charging Survey, V1.3 8

Combo 2 CHAdeMO + Type 2

Combined Charging Survey, V1.3 9

Combined Charging System CHAdeMO with separate charging systems

AC plus DC Charging DC Charging AC Charging

Consequences of a second separated charging system:

Combined Charging Survey, V1.3 10

Design of charging stations, V3.0 11

Combined Charging Survey, V1.3 12

The combo inlet fits behind typical fuel doors

Combined Charging Survey, V1.3 13

Combined Charging, Key Challenges of e-Mobility V0.4 14

Design of Charging System, V3.0 15

Design of Charging System, V3.0 16

Design of Charging System, V3.0 17

Design of Charging System, V3.0 18

Design of Charging System, V3.0 19

Design of Charging System, V3.0 20

Design of Charging System, V3.0 21

Design of Charging System, V3.0 22

Design of Charging System, V3.0 23

charger battery battery

Charging control requires a permanent communication between vehicle and charge

One communication system for all charging modes, world-wide:

PLC-based communication ISO/IEC 15118 for all charging modes applying

Combined Charging Survey, V1.3 24

Support of controlled intelligent charging based on dynamic rates

AC and DC Authentication with the same methods for AC and DC Charging

Certified payment and accounting system

Simple Using existing connections

Combined Charging Survey, V1.3 25

DC Charging and AC Charging use the same Smart Charge

TLS (Transport Layer

Combined Charging Survey, V1.3 26

Design of charging stations, V3.0 27

IEC 62196-1 IEC 62196-3

SAE J2847 SAE J2931 IEC 60529

Combined Charging Survey, V1.3 28

DC systems according to Combined Charging Systems will be created according to

Series production of DC-Charging ongoing, Transparent requirements for all

Series products available End of 2012