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© 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
© ABB Group 2009-07-14 | Slide 2
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
© ABB Group May 6, 2016 | Slide 5
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
© ABB Group 2009-07-14 | Slide 6
EV ChargingCharging station scheme
Power LineData Line
Company server
server
Charging station
Charge pole(s)
© ABB Group May 6, 2016 | Slide 7
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)
© ABB Group 2009-07-14 | Slide 8
EV ChargingContent
§ Overview§ AC charge pole definition§ AC charge pole development§ Solution from ABB LV Installation materials,
Beijing
© ABB Group 2009-07-14 | Slide 9
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
§ Overview§ AC charge pole definition§ AC charge pole development§ Solution from ABB LV Installation materials,
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
© ABB Group May 6, 2016 | Slide 13
§ 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
§ Overview§ AC charge pole definition§ AC charge pole development§ Solution from ABB LV Installation materials,
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 Group 2009-07-14 | Slide 23© ABB Group 2009-07-14 | Slide 23
ABB LV Installation Materials AC charger Product appearance
© ABB Group 2009-07-14 | Slide 24© ABB Group 2009-07-14 | Slide 24
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 Group 2009-07-14 | Slide 26© ABB Group 2009-07-14 | Slide 26
ABB LV Installation Materials AC charger System Integration – User interface
© ABB Group 2009-07-14 | Slide 27© ABB Group 2009-07-14 | Slide 27
ABB LV Installation Materials AC charger System Integration – User interface
© ABB Group 2009-07-14 | Slide 28© ABB Group 2009-07-14 | Slide 28
ABB LV Installation Materials AC charger System Integration – User interface
© ABB Group 2009-07-14 | Slide 29© ABB Group 2009-07-14 | Slide 29
ABB LV Installation Materials AC charger System Integration – User interface
© ABB Group 2009-07-14 | Slide 30© ABB Group 2009-07-14 | Slide 30
ABB LV Installation Materials AC charger System Integration – User interface
© ABB Group 2009-07-14 | Slide 31© ABB Group 2009-07-14 | Slide 31
ABB LV Installation Materials AC charger System Integration – User interface
© ABB Group 2009-07-14 | Slide 32© ABB Group 2009-07-14 | Slide 32
ABB LV Installation Materials AC charger System Integration – User interface
© ABB Group 2009-07-14 | Slide 33© ABB Group 2009-07-14 | Slide 33
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