E-Mobility

Module-4
Battery Charging Systems

-
Dr. Abhilash Krishna D.G.,
Assistant Professor,
Department of EEE, RVCE
CONTENTS

01 Requirements for Charging Charging Architectures

02
• Conductive Charging
• Inductive Charging
• Integral ac charging

Charger Functions Charger Standards

03 04
Requirements for Charging
System
Basic Requirements for Charging System
SAFTEY:
▪ This is the most serious consideration for any automotive manufacturer introducing an
electric vehicle (EV) to the consumer marketplace.
▪ The battery charger system must minimize the risk of electrical shock, fire, and injury to
the end user for a wide range of operating and fault conditions.
▪ The system must provide various levels of insulation and safety checks in order to ensure
a safe system.
▪ It is necessary to obtain safety approvals from the agencies (VIZ., Underwriters
Laboratories (UL) in the United States and VDE in Germany, ARAI in India etc.,) in order to
sell products in many countries.
Basic Requirements for Charging System
RELIABILITY:
▪ The automotive environment is very harsh.
▪ The same performance is expected whether a car is driven in the dry heat of the
Rajasthan, the freezing cold of Kashmir, or the humid conditions of Delhi.
▪ The car is exposed to significant shock and vibration in addition to corrosive solvents,
salt, water, and mud.
▪ The charger for the EV must have a long service life with daily operation.
▪ The electrical connector must be designed to withstand over 10,000 insertions and
withdrawals in these harsh conditions and still remain safe for the consumer.
Basic Requirements for Charging System
USER FRIENDLINESS:
▪ The present method of fueling a vehicle with an internal combustion engine is simple
and straightforward.
▪ EV charging must also be simple and should pose minimal challenge to EV users.
▪ Greater emphasis has to be placed on the ergonomics of refueling an EV compared to a
gasoline-fueled car.
Basic Requirements for Charging System
POWER LEVELS & CHARGING TIMES:
▪ The charging time for an EV can range from tens of minutes, if high-power charging is
used, to many hours, if low-power chargers are used.
▪ For EVs to gain widespread acceptance, the charging power levels should be maximized
in order to reduce the charging times.
▪ However, in practice the power levels can be limited by the household electrical wiring,
electrical grid impacts, battery chemistries and degradation due to high charging levels,
and, of course, size and cost.
Basic Requirements for Charging System
COMMUNICATION:
▪ At a basic level, the plug and cable assembly must not only transmit power, but must
also provide a communication path between the charger and the vehicle in order to
ensure a safe and optimized power flow.
▪ Simple messages relating to availability, maximum power output, charging time, and
problem or fault reporting are also critical communications.
Charger Architectures
Charger Architectures

Basic Topology
Charger Architectures
● The electrical grid provides alternating current (ac) voltages and currents at an electrical
frequency.
● Voltages and frequencies vary around the globe.
● The ac supply frequency is low and is typically 50 Hz or 60 Hz.
● A battery requires direct current (dc) electricity, and so, the first stage of the power
conversion is to rectify and filter the ac waveform from the grid to dc.
● Transformer is typically required to order to provide electrical safety to the user.
● Thus, the dc is chopped to create a stream of very high-frequency ac (hfac) waveforms.
● The high-frequency ac is rectified and filtered to create dc to supply the battery.
Charger Architectures
• There are a number of options for charging the vehicle, and there are a variety of charging
technologies available for EVs.
• Choices and decisions must be made by the various manufacturers, infrastructure providers, and
the consumers with respect to the following areas:
I. conductive or wireless/inductive charging
II. high-power or rapid charging
III. on-board versus off-board chargers
IV. integral charging
Charger Architectures – Conductive Charging

Conductive ac charging power block diagram

Charger Architectures – Conductive Charging
• Conductive charging is the common approach to charging a vehicle.
• Conductive charging simply means that the vehicle is electrically connected to the off-board
powering system by a conductive plug and socket assembly.
• Generally, vehicles feature a low-to-medium power onboard charger, with ac being supplied from
the electrical grid to the vehicle.
• An enabler for EVs is the capability to rapidly charge using a high-power charger.
• High-power chargers can be very large physically and are designed as stationary off-board
devices to be operated in a similar manner to a gasoline pump at a filling station.
• In this case, the charger is off-board, and dc is supplied on-board.
Charger Architectures – Conductive Charging(high-power)
Charger Architectures – Inductive Charging
● Wireless or inductive charging does not connect the vehicle to the electrical grid by a
conductive coupling using copper wires.
● Instead, the magic of transformer coupling is used to couple power from the grid to the vehicle
without conductive contacts.
● Such an approach can result in safety enhancements and consumer ease of use, but also
comes with significant engineering challenges.
● For wireless charging, the partition between the on-board and off-board components of the
charging system is within the transformer itself.
Charger Architectures – Inductive Charging
Charger Architectures – Integral Charging
● Integral charging was originally employed for the prototype predecessor of the GM EV1, known
as the GM Impact.
● The technology reconfigures the traction power electronics and machine to re-employ the
components to also perform the power conversions required for charging.
● Such an approach reduces the overall parts count on the vehicle while requiring additional
measures on electrical safety and isolation.
● A significant advantage of the integral charging approach is that the power flow can be made
bidirectional.
● Thus, the vehicle can supply power back to the local grid if required – such operation is known
as vehicle to grid (V2G).
Charger Architectures – Integral Charging
Grid Voltages, Frequencies
and Wiring
Grid Voltages, Frequencies, and Wiring

● Electrical equipment, especially mobile devices, are designed to operate globally.

● There are many configurations of wiring and voltage, power, and frequency around the world.
● First, the world is divided in terms of the electrical frequency of operation.
● Japan is the notable exception as it has two separate grids, one with 50 Hz to the east and one
with 60 Hz to the west.
● Similarly, the world generally operates with a standard voltage of 230 V (in the nominal range
of 220–240 V).
Grid Voltages, Frequencies, and Wiring

• The basic residential wiring system provides a phase voltage of

230 V, 50 Hz between the line and neutral.
• The neutral is typically grounded by physically connecting the
neutral to a copper grounding rod which is driven into the ground
at a location close to the residence.
• The three wires of line, neutral, and ground are hard-wired into the
charging assembly.
Grid Voltages, Frequencies, and Wiring
• The single-phase connection is typically provided by a
three-phase transformer.
• Commercial premises often have a three-phase
connection in order to power electric motors, fans,
compressors, and so on.
• The typical three-phase configuration is shown in Figure.
• Three phase can be an option for many charger power
levels,
• It consists of five wires of which three lines, neutral, and
ground are supplied to the charging equipment.
Grid Voltages, Frequencies, and Wiring
Charger Functions
Charger Functions
● EV chargers are similar in operation but have some key differences compared to battery
chargers used in other applications, such as mobile phones and laptop computers.

Low-power
charger
Charger Functions
● Ac-dc rectifier:
➢ The function of the ac-dc rectifier is to rectify, or make positive, the input ac voltage vac and
current iac when they are in the negative half cycle.
➢ Thus, the output of the diode rectifier is always positive, as can be seen in the waveforms
Charger Functions
● DC Capacitor:
➢ The dc capacitor is charged to the peak ac voltage when the rectified voltage │vac│
exceeds the capacitor voltage.
➢ This only happens during a portion of the cycle, and there is a surge of current from the
ac input through the diodes and into the capacitor.
➢ Thus, the current waveform has a sharp pulsed waveform.
Charger Functions
● DC – DC Converter:
➢ The dc-dc converter converts the high voltage on the dc capacitor to a safe lower voltage
for input to the laptop or mobile phone for use in charging.
➢ The simplest and most cost-effective dc-dc is the switch-mode flyback converter, which
switches at a high frequency and has the transformer isolation that is essential for safety.
Charger Functions – Low Power
● Summary:
➢ Thus, simple diode–rectifier–capacitor front-ends are only permitted in low-power
applications.
➢ At levels above hundreds of watts, the simple capacitive filter is buffered with another
switch-mode power converter, known as the boost converter.
➢ The boost converter serves to maintain the input current waveform identical with the input
voltage waveform and so eliminates any harmonic distortion and improves the power
factor to unity.
Charger Functions – High Power

Automotive standard charger

Charger Functions – High Power
Conductive battery charging system – EV Charger
Conductive battery charging system – EV Charger
● This charging system is representative of the on-board conductive systems.
● The circuit has a number of different functions as follows:
RCCB: The residual current circuit breaker (RCCB) detects an imbalance in the line and
neutral currents, usually between about 5 to 20 mA, and triggers a circuit breaker to take the
charger off-line to prevent fatalities. This circuitry is also known as a ground-fault circuit
interrupter (GFCI).
EMI filter: Switching power electronics can generate significant radiated and conducted
noise, known as electromagnetic interference. A high-current filter with common- mode and
differential-mode stages is required.
Conductive battery charging system – EV Charger
● Rectifier: A simple diode bridge rectifies the 50/60 Hz ac waveform.
● Boost PFC: A boost converter, typically switching at tens or hundreds of kHz, chops up the
low-frequency rectified power and boosts it to a voltage level of about 400 Vdc, a value higher
than the peak ac value.
● Dc link: An electrolytic capacitor is usually used for bulk storage to filter the 50/60 Hz
component.
● Dc-hfac chopper: A full-bridge or H-bridge converter is used to chop the nominal 400 V dc link
voltage into a high-frequency pulse stream going from -400 V to +400 V at the switching
frequency.
Conductive battery charging system – EV Charger
● Transformer: the high-frequency pulse stream is galvanically isolated for safety by the
transformer.
● Rectifier-filter: The output of the transformer secondaries are rectified and filtered to create
dc current to charge the battery.
Charging Standards and Technologies
● A number of charging standards have emerged or are emerging globally.
● A global standard, IEC 62196, has been developed by the International Electrotechnical
Commission (IEC) and acts as an umbrella standard for a number of the charging standards.
● The global standard covers the basics of power and communication interfaces.
● Various charging standards describe the mechanical and electrical specifications of the
particular plug and socket assemblies.
● The main charging standards are
▪ SAE J1772 - ac and dc charging
▪ VDE-AR-E 2623-2-2 - single-phase and three-phase ac charging
▪ JEVS G105-1993, known as CHAdeMo - globally for high-power dc charging
SAE J1772
● This standard has been developed by the Society of Automotive Engineers (SAE) for use in
North America.
● The standard covers a number of different power levels.

S.No. Voltage Max. Continuous Current

Ac Level 1 120 V (input ac) 12/16 A (input ac)
Ac Level 2 240 V (input ac) <80 A (input ac)
Dc Level 1 50–500V (output dc) 80 A (output dc)
Dc Level 2 50–500V (output dc) 200 A(output dc)
SAE J1772
● Level 1 charging is for low-power convenience charging using a standard 120 V outlet and
supplying up to 1.44 kW or 1.96 kW maximum.
● Level 2 standard installed home charger would feature up to 19.2 kW, if available.
● Above these power levels, the standard includes options for high-power off-board dc charging.
● The SAE standard also enables use of a combined socket featuring ac and dc which is known
as the SAE J1772 Combo or CCS Combo.
• The SAE J1772 Level 2 plug features three power contacts – line,
neutral, and ground and two signal contacts.
SAE J1772 Level 2 socket
VDE-AR-E 2623-2-2
● The VDE-AR-E 2623-2-2 standard has been developed for use in Europe.
● It facilitates the use of three phase, in addition to single phase, as three phase is widely
available in parts of Europe.
● The standard includes five power wires – three lines, a neutral, and a ground – and two signal
wires.
CHAdeMo
● Several thousand high-power chargers have been installed globally using the CHAdeMO
standard.
● The basic high-power charger is 40 kW. The 40 kW charger, plug, and socket are shown
below:

off-board dc charger plug

on-board socket
Wireless Charging
● Inductive:
▪ Wireless charging or inductive charging is a method of transferring electrical power from
the source to the load magnetically rather than by direct ohmic contact.
▪ The technology offers the advantages of galvanic isolation, safety, connector robustness,
and durability in power delivery applications where harsh or hazardous environmental
conditions may exist.
▪ Examples of these applications are mining and sub-sea power delivery and EV battery
charging.
▪ The basic principle underlying inductive coupling is that the two halves of the inductive
coupling interface are the primary and secondary of a separable two-part transformer.
Wireless Charging
● When the charge coupler (i.e., the primary) is juxtaposed with the vehicle inlet (i.e., the
secondary), power can be transferred magnetically with complete electrical isolation, as with a
standard transformer.
● The coupler and vehicle inlet featured in the EV1 are shown in below Figure

● The coupler is attached via the cable to the off vehicle

charging module.
● When the coupler is inserted into the vehicle inlet, power
from the coupler is transformer-coupled to the secondary,
rectified, and fed to the battery by the battery cable.
THANK YOU