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ELECTRIC VEHICLE CHARGER

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ELECTRIC VEHICLE CHARGER

BY

DR. AMAN JHA


HEAD-R&D ELECTRICAL AND ELECTRONICS ENGINEERING
BRANDENBURG INNOVATIONS, BENGALURU, INDIA
SR. MEMBER IEEE, PES, POWER ELECTRONICS SOCIETY
OUTLINE

• EV Charging • Smart Charger (V2X)


• Classification & Comparison • Benefits
• On Board Charger (AC) • Application of V2X
• Architecture • Charging Standard
• Block Diagram • SAE Standard
• Discussion on Topologies • Charging Characteristics
• OFF Board Charging (DC) • Power of EV Chargers
• Architecture • Indian Perspective
• Block Diagram • Future E- Car
• Discussion on Topologies
2
OUTLINE

• EV Charging • Smart Charger (V2X)


• Classification & Comparison • Benefits
• On Board Charger (AC) • Application of V2X
• Architecture • Charging Standard
• Block Diagram • SAE Standard
• Discussion on Topologies • Charging Characteristics
• OFF Board Charging (DC) • Power of EV Chargers
• Architecture • Indian Perspective
• Block Diagram • Future E- Car
• Discussion on Topologies
3
CHARGING SCHEMES
On Board Charger
DC Charger

ON-BOARD CHARGER

Battery Pack
Inductive pick-up

Wireless Charging
Charging inductor

4
CLASSIFICATION

• Charging Scheme • Charger Presence


• Conductive (AC and DC) • On-Board Charger (OBC)

• Charging station, Off-Board Charger (DC Charger)


• Inductive (Static & Dynamic)
• Wireless
• Battery Swap (Mechanical)

Images for representation purpose only


CONDUCTIVE AC CHARGING
On-Board Charger (OBC)

• The battery can be recharged anywhere


• Easy communication with Battery Management
System
• No additional power electronic converters
• Higher performance and lower cost
• Power level limitation
• Size and weight restrictions
• Relatively long charging time

Images for representation purpose only


CONDUCTIVE DC CHARGING
Off-Board Charger

• Design specific for high or low


charging rate
• Not limited to weight and size
• Made for fast charging
• High installation cost
• Adverse impact on power system
• Reliable communication is important
(BMS to battery)

7 purpose only
Images for representation
STATIC INDUCTIVE CHARGING
Wireless Static

• Convenience
• No manual intervention
• High investment
• Limited space & weight of charge pads
• Misalignment between the vehicle and the
charge pad
• Power losses and relatively lower
efficiency than conductive charging
• Electromagnetic radiation exposure
8
Images for representation purpose only
DYNAMIC INDUCTIVE CHARGING
Wireless Dynamic

• Low stand-in charging time


• Low battery DoD
• Smaller battery size
• High investment
• Foreign objects change coil structure
and coil misalignment on the road
• Applicability to different car types
• Experimental Stage

9
Images for representation purpose only
BATTERY SWAP

• No range anxiety
• Quick and easy refilling like a combustion
engine car tank
• Longer charging times available for the EV
battery compared to fast DC Charging
• Standardized battery interface
• Consumer acceptance

Images for representation10


purpose only
COMPARISON CHART
Charging Methods Conductive Inductive Battery Swap

AC DC Static Dynamic

Convenience
Cost
Service time Long Short Long Flexible Shortest
Power Level
Efficiency
Battery Lifetime
Standardization
Impact on Grid

11
OUTLINE

• EV Charging • Smart Charger (V2X)


• Classification & Comparison • Benefits
• On Board Charger (AC) • Application of V2X
• Architecture • Charging Standard
• Block Diagram • SAE Standard
• Discussion on Topologies • Charging Characteristics
• OFF Board Charging (DC) • Power of EV Chargers
• Architecture • Indian Perspective
• Block Diagram • Future E- Car
• Discussion on Topologies
12
OBC ARCHITECTURE

Electric Vehicle

Charge Onboard BMS


AC controller Comm.
Charger Power Control
Charging
Unit
Station

Safety
Interlocks
Protection
circuits
DC CC/CV Battery
AC Supply
AC Rectifier DC DC-DC
Converter

13
BLOCK DIAGRAM
OBC
Main Power Stages Block Diagram
High Voltage Key Features
DC bus
➢ OBC is an AC-DC converter composed by
(200-450V)
(PFC + isolated DC-DC) main stages
PFC DC-DC
➢ Power level up to 22kW
➢ Input voltage
▪ EU: 230 Vac or 400 Vac
AC input voltage Aux Power Supply ▪ US: 120Vacor 240 Vac
(single or 3 phase) ➢ Voltage output range: 200VDC-450VDC
~
➢ High effciency
EV
➢ AEC-Q101 power discrete devices
required
➢ AEC-Q100 integrated circuits required
➢ Minimal size
14
PFC TOPOLOGIES
Power Level
2-3.6 kW 6.6-7.2 kW 10-11 kW 20-22 kW
Most Common PFC Topologies

Interleaved Boost
(single phase input)

Semi-bridgeless
(single phase input)

Totem Pole
(single phase input)

Vienna modified
(3 phase input)

Vienna original
(3 phase input)
15
INTERLEAVED BOOST: PFC
Pros & Cons

• 2 Parallel Connected Boost Topologies


180° Phase Shifted (or N Boost 360°/N
Shifted)
• Reduced Input Current Ripple
• Reduced Capacitive Ripple
• Reduced Inductor Size
• Better Heat Dissipation
• High Losses In Bridge Diode Rectifier
• Increased components

16
SEMI-BRIDGELESS BOOST PFC
Pros & Cons

• 2 Boost Topologies
• Bridge Rectifier Removed
• Reduced Inductor Size
• Better Heat Dissipation
• Increased Components
• Less EMI Issue

17
TOTEM POLE BRIDGELESS BOOST PFC
Pros & Cons
• Bridge Rectifier Removed
• Reduced Part Count
• Very Small Conduction Losses
• Very High Efficiency
• Small EMI
• Body Diodes used as Fast Recovery
Diodes
• Complex Drive and Sampling Circuit

18
DC-DC TOPOLOGIES VS POUT

Most Common OBC Power Level


Most Common DC-DC Topologies

2-3.6 kW 6.6-7.2 kW 10-11 kW 20-22 kW

Full bridge-LLC

Full bridge-PS

3 level
Half bridge-LLC

19
AUXILIARY SMPS : POWER LEVEL

< 15W 15W - 70W

Flyback
based on converter

Flyback
based on discrete
controller + MOSFET

20
(3PH + NEUTRAL) INPUT: MODULAR

L1 Vdc
PFC DC-DC
N 1 1
• Easy system implementation
• More system reliability
• Higher system efficiency
L2 PFC DC-DC
N
2 2

L3 PFC DC-DC
N 3 3

21
AC CHARGING CONNECTOR

• Type 1 • Tesla US • Type 2


• 120V/240V 1P/80A Connector • 3P 240V/80A;
• Used in USA & Japan • 17.2kW/240V 400V/63A
• Used in China Europe

22
CONTROL PINS

Proximity Pilot

Monitor Connection Between EV


& Charger
Two Signals

Maximum Actual Charge


Control Pilot Charge Current
Current
PWM Signal
23
OUTLINE

• EV Charging • Smart Charger (V2X)


• Classification & Comparison • Benefits
• On Board Charger (AC) • Application of V2X
• Architecture • Charging Standard
• Block Diagram • SAE Standard
• Discussion on Topologies • Charging Characteristics
• OFF Board Charging (DC) • Power of EV Chargers
• Architecture • Indian Perspective
• Block Diagram • Future E- Car
• Discussion on Topologies
24
DC CHARGING ARCHITECTURE

Charge
Communication
controller
BMS

Power Control
DC Charging Station Unit
Electric
Safety Vehicle
Interlocks

Variable
DC Supply Protection
AC Supply AC Rectifier DC DC-DC DC DC
circuits
CV?CC Battery
Converter
25
BLOCK DIAGRAM
Three phase PFC Isolated DC/DC
L1
SiC diodes SiC Diodes
HV MOSFETs SiC MOSFET
L2 HV diodes HV diodes
/ IGBTs
SCRs 200-500Vdc
L3

Signal MOS/IGBT MOS/IGBT Signal


Control unit
conditioning Gate driver Gate driver conditioning

AC

Auxiliary Supply

Diode Diode
Clamp
`
AC
CV
Controller HV MOSFET Controller
Reference

26
PFC CONVERTER
Three phase PFC Isolated DC/DC
L1
SiC diodes SiC Diodes
HV MOSFETs SiC MOSFET
L2 HV diodes HV diodes
/ IGBTs
SCRs 200-500Vdc
L3

Signal MOS/IGBT MOS/IGBT Signal


Control unit
conditioning Gate driver Gate driver conditioning

AC

3.3 VDC for MCUs


Auxiliary Supply 15V for relays and gate -5..20 VDC for Sic
drivers 0..15V for Si
Diode Diode
Clamp Auxiliary Supply for Drivers
`
AC
CV DC/DC
Controller HV MOSFET Controller
Reference + switching
regulator
Diode

27
DC/DC CONVERTER
Three phase PFC Isolated DC/DC
L1
SiC diodes SiC Diodes
HV MOSFETs SiC MOSFET
L2 HV diodes HV diodes
/ IGBTs
SCRs 200-500Vdc
L3

Signal MOS/IGBT MOS/IGBT Signal


Control unit
conditioning Gate driver Gate driver conditioning

AC

3.3 VDC for MCUs


Auxiliary Supply 15V for relays and gate -5..20 VDC for Sic
drivers 0..15V for Si
Diode Diode
Clamp Auxiliary Supply for Drivers
`
AC
CV DC/DC
Controller HV MOSFET Controller
Reference + switching
regulator
Diode

28
AUXILIARY POWER SUPPLY
Three phase PFC Isolated DC/DC
L1
SiC diodes SiC Diodes
HV MOSFETs SiC MOSFET
L2 HV diodes HV diodes
/ IGBTs
SCRs 200-500Vdc
L3

Signal MOS/IGBT MOS/IGBT Signal


Control unit
conditioning Gate driver Gate driver conditioning

AC

Auxiliary Supply

Diode Diode
Clamp
`
AC
CV
Controller HV MOSFET Controller
Reference

29
DC CHARGING CONNECTORS

• CCS –COMBO1 (USA) • CCS –COMBO2 (EU)


• 200-1000V/350A up to 350kW • 200-1000V/350A up to 350kW

• China GB/T
• 50-500V/400A
• Future 1000V/400A

• Chademo (Japan)
• 50-500V/400A
• Future 1000V/400A 30
OUTLINE

• EV Charging • Smart Charger (V2X)


• Classification & Comparison • Benefits
• On Board Charger (AC) • Application of V2X
• Architecture • Charging Standard
• Block Diagram • SAE Standard
• Discussion on Topologies • Charging Characteristics
• OFF Board Charging (DC) • Power of EV Chargers
• Architecture • Indian Perspective
• Block Diagram • Future E- Car
• Discussion on Topologies
31
SMART CHARGING V2X

▪ Increase the flexibility of charging. Bulk Renewable


Generation

▪ Higher utilization rates of fixed assets.


▪ Increase the efficiency of power transfer.
▪ Reduce the peak demand on the distribution Generation

network.
▪ EVs can be made more sustainable by
charging by renewable. Storage Prosumers

Distributed Renewable
▪ Smart charging can provide new revenue Energy Generation Prosumers

streams to EV owners. Electric Vehicles 32

Images for representation purpose only


APPLICATION OF V2X

• Local load balancing


• Adjust charging time/power according to load
• Balance multiple charge points with priority
• Renewable energy utilization
• Price based charging
• Peak saving
• Grid back up

33
LOAD BALANCING

• Shift the charging time slot and to adjust the charging


power based on the grid capacity and local loading
condition
• The second approach is to balance multiple charge points
with priority

34
UTILIZATION OF RENEWABLE ENERGY

▪ Smart charging can help in controlling


the charging power of the car based on
the renewable energy production, say
from solar and wind generators.

▪ V2G, the electric cars can be used as


massive energy storage to balance the
variable generation from renewable
energy sources.

35
PRICE BASED CHARGING

▪ The charging power is increased when the


electricity price is low, and the charging
power is decreased or even stopped when
the electricity price is high.

▪ Customers can get more profit when the V2x


is applied. For example, we can charge the
cars when the electricity is cheap and
discharge the car via V2x when electricity is
expensive and above a certain pricing level.
36
PEAK SAVING

▪ The aggregated EVs can work as mass


storage in the grid. With controlled charging,
the EVs can be charged when there is extra
renewable energy generation, and they can
discharge via V2X to feed the grid when a
peak load is in the evening.

▪ By doing so, the peak of both generation


and consumption can be shifted, and the
electric power demand-supply gap can be
perfectly matched. 37
GRID BACK-UP

▪ In the future, electric vehicles can even


operate as a backup for the grid on a
relatively large scale.

▪ In case of a short duration failure, EVs can


be connected to the grid, to our homes or to
loads and can be controlled to provide
emergency power via V2X.

38
OUTLINE

• EV Charging • Smart Charger (V2X)


• Classification & Comparison • Benefits
• On Board Charger (AC) • Application of V2X
• Architecture • Charging Standard
• Block Diagram • SAE Standard
• Discussion on Topologies • Charging Characteristics
• OFF Board Charging (DC) • Power of EV Chargers
• Architecture • Indian Perspective
• Block Diagram • Future E- Car
• Discussion on Topologies
39
SAE STANDARD
AC Charging
Power level
Voltage Levels (V) Typical usage Interface
(kW)
Level 1: Convenient
230 (EU) Office or Home base 1.4 (12A)
Any convenient outlet
120 (US) charging 1.9 (20A)
Level 2: Main
4 (17A)
400 (EU) Public and private based Electric vehicle supply
8 (32A)
240 (US) charging equipment
19.2 (80A)
Level 3: Fast
Like a filling station Electric vehicle supply 50
208 - 600
commercial point equipment 100 40
SAE STANDARD
DC Charging

Voltage Levels (V) Typical usage Interface Power level (kW)

Dedicated Electric vehicle supply


Level 1: 200 - 450 40
charging stations equipment

Dedicated Electric vehicle supply


Level 2: 200 - 450 90
charging stations equipment

Dedicated Electric vehicle supply


Level 3: 200 - 600 240
charging station equipment

41
IEC AND CHADEMO STANDARDS
Voltage Levels (V) Location of Charger Typical usage Interface Power level (kW)
IEC
AC Charging
Single Phase Office or Home base
Level 1 Any convenient outlet 4 – 7.5 (16A)
On board charging
Single Phase/ Three Publically and
Electric Vehicle Supply
Level 2 Phase privately based 8 – 15 (32A)
Equipment
On board charging
Three Phase Like a filling station, Electric Vehicle Supply
Level 3 60 – 120 (250A)
On board Commercial point Equipment
DC Charging
Dedicated Charging Electric Vehicle Supply
Rapid Charging Off board 1000 – 2000 (400A)
stations Equipment
CHAdeMO Standard
Dedicated Charging Electric Vehicle Supply
DC Rapid Charging Off board 62.5 (125A)
stations Equipment 42
OTHER SYSTEM LEVEL STANDARDS
EV infrastructure safety, electrical This standard is related to safety of
IEC TC 69/64 SAE J-2929
installation, electric shock protection. propulsion battery system.

This standard deals with electrical safety of


Standards related to workplace safety, SAE J-2910
buses and test for hybrid electric trucks.
NFPA 70/70E charging system safety, branch circuit
protection. SAE J-2344 Defines rules for EV safety.

Standard is related to protection of Standard defines the safety rules for


UL2202 SAE J-2464
charging system. Recharge Energy Storage Systems (RESS).

This standard deals with protection of Standard is related to electrically propelled


UL2231
supply circuits. ISO 6469-1: 2009 (IEC) road vehicles, on board RESS, inside and
outside protection of a person.
It provides rules of protection regarding Safe operation of EVs, provide protection
UL225a ISO 6469-2: 2009 (IEC)
couplers, plugs and receptacles. against inside failures.

Provides safety regulations for battery ISO 6469-2: 2001 (IEC) Electrical hazard protection.
DIN V VDE V 0510-11
installation and secondary batteries. 43
OUTLINE

• EV Charging • Smart Charger (V2X)


• Classification & Comparison • Benefits
• On Board Charger (AC) • Application of V2X
• Architecture • Charging Standard
• Block Diagram • SAE Standard
• Discussion on Topologies • Charging Characteristics
• OFF Board Charging (DC) • Power of EV Chargers
• Architecture • Indian Perspective
• Block Diagram • Future E- Car
• Discussion on Topologies
44
CHARGING CHARACTERISTICS
Level 1 Charging Level 2 Charging DC Fast Charging
Battery
All Electric Connector
Product type & Charge Charge Charge
range type Demand Demand Demand
Energy Time Time Time

Toyota Prius
Li-Ion 1.4 kW 3.8 kW
PHEV 14 miles SAEJ1772 3 hours 2.5 hours N/A N/A
4.4 kWh (120 V) (240 V)
(2012)

Chevrolet Li-Ion 0.96 – 1.4


40 miles SAEJ1772 5 – 8 hours 3.8 kW 2 – 3 hours N/A N/A
Volt PHEV 16 kWh kW

Mitsubishi i- Li-Ion SAEJ1772


96 miles 1.5 kW 7 hours 3 kW 14 hours 50 kW 30 minutes
MiEV EV 16 kWh JARI/TEPCO

Nissan Leaf Li-Ion SAEJ1772 12 – 16 15 – 30


100 miles 1.8 kW 3.3 kW 6 – 8 hours 50+ kW
EV 24 kWh JARI/TEPCO hours minutes

Tesla Li-Ion 9.6 – 16.8 4 – 12


245 miles SAEJ1772 1.8 kW 30+ hours N/A N/A
Roadster EV 53 kWh kW hours
45
POWER OF EV CHARGERS
DC, FC and HPC are CharIn Standards

???
Supercars, busses, trucks

Medium size
E-bike cars
E-motorbike
Light EVs

???
EV INDIAN PERSPECTIVE

▪ Government of India aspires to have 100% EVs by 2030


▪ According to National Electric Mobility Mission Plan
▪ Every car sold in India from 2030 will be electric, under new government plans.
▪ India aims to become a 100% electric vehicle nation by 2030. The National Electric Mobility Mission Plan (NEMMP)
targets seven million electric and hybrid vehicles by 2020.

▪ It is estimated that the replacing these 500,000 cars with EVs over the 3-4-year period will lead to fuel savings of
about 8000 million liters, 10 million tons of CO2 reduction and 28,200 crore of annual fuel savings
▪ Energy Efficiency Services Ltd (EESL), a joint venture of PSUs of power ministry, has placed an order for 10,000
electric vehicles

▪ Tata Motors wins order for 10,000 electric vehicles from EESL
47
SMART CITIES AND E-RICKSHAW

▪ Smart E- Rickshaw with charging station/ e-rickshaws / Electric vehicles for last mile
connectivity is the requirement coming from approximately coming from 20 Smart
Cities out of 100 Smart Cities
▪ There is proposal for a Quick Pilot on EV Charging Infrastructure in the Gurgaon-IGI-
South Delhi-Noida corridor by NITI Aayog

48
OUTLINE

• EV Charging • Smart Charger (V2X)


• Classification & Comparison • Benefits
• On Board Charger (AC) • Application of V2X
• Architecture • Charging Standard
• Block Diagram • SAE Standard
• Discussion on Topologies • Charging Characteristics
• OFF Board Charging (DC) • Power of EV Chargers
• Architecture • Indian Perspective
• Block Diagram • Future E- Car
• Discussion on Topologies
49
BODY AND CONVENIENCE

50
ELECTRO-MOBILITY

51
IN-VEHICLE INFOTAINMENT

52
TELEMATICS AND NETWORKING

53
ADAS

54
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56
CONTINUED…

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57
CONTINUED...
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Automation & Power Engineering (RDCAPE), NOIDA, India, 2019, pp. 131-136.

58
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