EV infrastructure - AC charger ABB

© ABB Group 2009-07-14 | Slide 1

Low Voltage ProductsEV charging infrastructureSolution for AC charging

D. Malacalza, J. Fan, ABB Low Voltage Installation Materials Ltd (Beijing), Aug 2011


EV ChargingContent

§ Overview§ AC charge pole definition§ AC charge pole development§ Solution from ABB LV Installation materials,

Beijing

© ABB Group May 6, 2016 | Slide 3© ABB Group May 6, 2016 | Slide 3

BackgroundEnvironmental concerns

Road transport is an increasing source of CO2 emissions

Annu

al e

mis

sion

of C

O2

in G

igat

ons

Electricity plants

Industry (excl. cement)Road transportResidential and service sectorDeforestation OthersRefineries etc

International transport

10

9

8

7

6

5

4

3

2

1

01970 1980 1990 2000

Source: IPCC “Mitigationof Climate Change”,Cambridge UniversityPress, 2007

© ABB Group May 6, 2016 | Slide 4

Lochner-Porsche 1stPHEV

GMXP883electricmotorpoweredthecaruntilitreached16km/h,atwhichpointthegasolineenginewouldkickinwhenrunninginhybridmode.

EsoroH301 bytheSwisscompanyEsoroAG.9kWhNi-Cdbatterycouldberecharged in4hfroma220velectricalwalloutlet,orinabout2hatasteadyspeedof120km/h.

Audi Duo twiceexpensiveA4diesel

Renault Kangoo onboard3.5kWchargercouldchargeadepletedbatterypackinabout4hfrom220volts.

ToyotaPrius+ hada15kmrangeusingLead-acidbatterypack.Calcarsinitiative

ToyotaPrius hadaA123Li-ionpack

for25km

Chevrolet Volthada65kmrangeusingLi-ionbatterypack.Starts2010

ManycarmanufacturersannouncedcommercializationofPHEVin2009-2010:Toyota,GM,VW,Mazda

Theelectricautomobileisinitsheyday.Ofthe4,192carsproducedintheUS28%arepoweredbyelectricity,andelectricautosrepresentabout1/3ofallcarsfoundontheroadsofNewYorkCity,Boston,andChicago.

Theelectric carceasestobeaviablecommercialproduct.Theelectric car'sdownfallisattributable toanumberoffactors,includingthedesireforlongerdistancevehicles, theirlackofhorsepower,andthereadyavailabilityofgasoline.

1890 1900 1920

Concernsaboutthesoaringpriceofoilandagrowingenvironmentalmovement resultinrenewed interestsinelectriccarsfrombothconsumersandproducers.

VanguardCitiCar hadatopspeedof50km/handareliablewarm-weatherrangeof65km.

19701974

GMEV1 hadarangeof260 kmwithNi-MHbattery

1994 1997 1999

REVAiisthebestsellingEV (lead-acidbattery, topspeed80km/h,range80km,recharge time8h,priceinUK≈12000€

2001 2003 2004 2005 2006 2007 2008 2010

SmartEV (zebrabattery,topspeed120km/h,range110km,rechargetime8h)

Mitsubishi iMiEV (16kWhLi-ionbattery,topspeed130

km/h, range130km)Nissan,Toyota,GM,Mitsubishiand11newcompaniesplanningtoofferhighway-capableEVwithinafewyears.

ZENN (lead-acidbattery, topspeed40km/h,range60km, recharge time8h,15000$

Background Electric vehicles history


Description Installation

Slow charging(on-board)

Individual poles at home or at parking lotsFull battery charge >6 hours

2 - 4 kW, normal residential & office installationsSmall converters

Fast charging(on-board)

Special charging stations / special equipment at homeNow fastest charge ca. 30 min, typical 1 hr

7.2 - 43 kWOnboard converter becomes expensive component for higher powers

Fast and Ultra-fast charging(off-board)

Special charging stations (option: integration of energy storage)Concept to reduce charging time to ca. 6 minutes – near parity with ICE refueling

50 - 250 kW+Off-board DC convertersImproved performance, lower system costs

Battery replacement

Stations for replacement of depleted batteries Main application: highways

Larger stations on the MW rangeMV installations and larger convertersVision: robotic solution to replace batteries

BackgroundCharging methods


EV ChargingCharging station scheme

Power LineData Line

Company server

server

Charging station

Charge pole(s)


Our offeringEV charging infrastructure solution

Substation Network mngt,authentication & billing

Renewable energysources

Public ACcharging pole3-20kW

DomesticAC wallbox

3 - 4 kWPublic DCcharging station50 - 300 kW

Energystorage & power quality

Battery swap stations for public transportation

Linking charging infrastructure to Building-Energy-Mgmt-Systems

Used car batteries as central storage capacity

Storage of peak supply power in car batteries (V2G)


EV ChargingContent


Beijing


EV Charging poleCar Charging Outlet Unit (charger) - Definition

§ A charger is an access point to electric power.§ The access is provided through a plug and socket combination.§ The energy consumption is measured by an electric meter function.§ The energy flow is controlled by a switching device (on/off)§ The charger (socket) is protected by short circuit, overload and residual

current protection.§ Overvoltage protection by surge protection devices can be provided if

required.§ Authentication devices (RFID transponder/tag, credit card reader)§ A communication function (eg. GPRS) exchanges information between

charger and system.§ A control function does:

§ authentication (in interaction with the management system),§ provides the measured/consumed charged electricity to the

management system,§ provides monitoring/diagnostics of the charger

§ Above components are housed in a charge pole

© ABB Group 2009-07-14 | Slide 10

EV Charging poleClassification of Charge spots

§ Home/residential

§ In-house (garage) or outdoor (street parking, car port)

§ No authentication necessary

§ Energy measurement (sub-metering) and control part of the SmartHome

§ Few charge points per home / flat

§ Business, Public (outdoor, indoor)

§ Company parking

§ Public building, stores, malls

§ Car parks

© ABB Group 2009-07-14 | Slide 11

EV ChargingContent


Beijing

© ABB Group 2009-07-14 | Slide 12

The product structure of a charge pole can be broken down in the following functional areas:

§ Standard components for electrical distribution (RCBO, MCB, etc)

§ Standard components for automation/communication (PLC, Meter, KNX modules, etc.)

§ Socket outlet / Coupler§ Additional functions (authentication, communication, HMI, etc)

§ System Integration level 1: communication with PLC

§ System Integration level 2: user interface, billing

§ External case

Development of a charge pole is organized accordingly

AC Charging poleCharge pole structure


§ IEC Standards:§ IEC 61851-1/2§ IEC 62196-2

§ China:§ China: GB/T XXXX – 201X Electric Vehicle Conductive Charge

Coupler (draft version).§ China: GB/T XXXX – 201X Communication Protocols between

Battery Management System and Off-board Charger for Electric Vehicles (draft version)

§ ……§ America/Japan:

§ SAE J1772 (medium on-board: 3-4 h)§ CHADEMO (TEPCO/Japan: fast off-board: <30 min)

EV Charging Pole Standardization issue

© ABB Group 2009-07-14 | Slide 14

NL3L2L1

AC charge pole Block diagram

MCB = Miniature Circuit BreakerRCBO = Residual Current operated circuit Breakers with Overcurrent protectionPWR = Power Supply 230 V AC / 24 V DC

Socket outlet

PE

P

PN

N

PE

P

P

P

N

N

N

RFID tag, credit card, etc.

GPRS, Power Line, etc.

Sensors, cooling, heating

car communication

Con

nect

or

Mai

n Sw

itch

MC

B 1A

RC

BO 1

0 A

/ 16

A, 3

0 m

AR

CBO

32

A,30

mA

Elec

trici

tyM

eter

Elec

trici

tyM

eter

Con

tact

orC

onta

ctor

Control

Authentication

Communication

PWR

Auxiliary

AC500-eCo PLC§ Authentication of the user by

RFID-chip, verification with service provider, allow or refuse charging

§ Read out of charged electricity and communicate it with the service provider using wireless GPRS communication or build-in Ethernet (cable) or other fieldbus

§ Load control and charger status (available, occupied, out of service, charge current)

§ Communication with the Electric Vehicle for safe connection and correct charging

§ Allows remote diagnostic of charger

GPRS-modem

AC500-eCo

RFID authentication

RCD automatic reset and remote

DS200 RCD with automatic reset and remote control

§ Either resets automatically in a defined sequence or controlled by the AC500

§ Monitoring if tripped

Electricity meter§ Measures the charged electric

power (single phase or 3-phase)

§ Measures actual line voltage and actual charge current

Electricity meter

AC Charge poleDistribution/automation components

§ Electronic meter with four quadrant metering meaning that the meter can measure both imported as well as exported energy for active or active and reactive energy

§ Type approved according to international standards. Approved according to MID

§ Class B and A according to EN 50470-1, -3, Class 1 and 2 according to IEC

§ Remote reading via pulse output or communication

§ Communication via infrared port or via built-in interface Communication modules that connect via infrared port to the meter for remote reading and setting of data in the meter

AC Charge poleElectricity meter

User identification and authorization to charge could be managed through:

§ Sinopec card (中国石化加油卡)

§ ATM card (connection to the bank server required)

§ Beijing “all-in-one” card (市政交通一卡通)

§ Credit card (VISA, AMEX, etc)

§ Any other system to be defined according to the local habits/needs

AC Charge pole Authentication (example)

AC500 PLC§ Scalable control

§ Wide choice of communication and field bus couplers

§ User-selectable coupler types for simultaneous operation

§ Fast replacement thanks to plug-in modules

§ A single software package for the entire range

§ Seamless integration of control system and field devices

AC Charge pole Automation/control

© ABB Group 2009-07-14 | Slide 19

Highlights in AC charge pole product development

§ Current market evolution doesn’t allow to define a specific charge pole suitable to any installation

§ Functional areas are well identified

§ The type of component suitable to satisfy the specific function can change according to the needs of the installation under consideration

§ All the charge pole components are available on the market

AC Charge pole Product Development

© ABB Group 2009-07-14 | Slide 20

AC Charge pole Product Development

Reference standards

§ IEC 62196 (Plugs, socket-outlets and vehicle inlets –Conductive charging of electrical vehicles)

§ IEC 61851 (Electrical Vehicle Conductive Charging System)

§ China: GB/T XXXX – 201X Electric Vehicle Conductive Charge Coupler (draft version).

§ China: GB/T XXXX – 201X Communication Protocols between Battery Management System and Off-board Charger for Electric Vehicles (draft version)

§ Other standards (i.e. SAE, UL where required)

© ABB Group 2009-07-14 | Slide 21

EV ChargingContent


Beijing

© ABB Group 2009-07-14 | Slide 22© ABB Group 2009-07-14 | Slide 22

ABB LV Installation Materials AC charger Product characteristics

§ Charging voltage: 200-240VAC

§ Charging current:16 / 32A

§ Protection: IP44

§ Charging interface: 7 pins

§ User authentication: RFID

§ Residual current: 30mA

§ Surge protection function

§ Bill printing function

§ HMI display

Function can be specialized according to customer’s requirement


ABB LV Installation Materials AC charger Product appearance


n ABB PLC (PM564-T-ETH CPU) act as central control unit

ABB PLC

Phys. interface Protocol

IEEE 802.3 M-Bus

RS485 Proprietary

DO control N/A

RS485 Proprietary

GB/T XXXX-201X 5.2.1 N/A

RS485 Modbus

Authentication (RFID)

Electricity Meter

Communication with Sever (GPRS/Internet)

Contactor

PWM signal

HMI

Device

ABB LV Installation Materials AC charger System Integration – Interface and Protocols

© ABB Group 2009-07-14 | Slide 25

Main functions of the user interface:§ User authentication through RFID§ Lock/Unlock door to access the socket outlet

§ Different charging solutions available for billing: the user select which charging solution is the most suitable:

§ Power (input of the kWh needed)§ Time (input of the duration of the charge)§ Money (input of the amount of money to be charged)§ Full charging ( Charging until Battery is full)

§ Charging status with posibility to stop the operation§ Printing of the invoice/result of the charging operation if

requested

ABB LV Installation Materials AC charger System Integration – Interface and Protocols


ABB LV Installation Materials AC charger System Integration – User interface














EV Charging AC Charge pole – Product Offer

Bas

ic

func

tiona

litie

s

Com

plet

e po

le

Protection

Socket Outlet

Automation/Control

PLC Integration

Authentication/CommunicationUser Interface Integration

External case

The current product structure will allow to organize an offer fitting to all the possible customer needs

© ABB Group 2009-07-14 | Slide 34

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EV infrastructure - AC charger ABB