EV Charging design infrastructure – Safety Standards
With the electronic vehicle (EV) market becoming more significant in Europe in the last few years, the need for charging points is steadily increasing. The demand for the infrastructure is mostly due to the uptake of electronic vehicles as more car manufactures are now focusing their efforts in EV’s to meet EU demands. It is also evident that with surges in new EV cars sales also requires further expansion to the infrastructure, including new accessible charging points and expansion of existing charging points.
The overall infrastructure of EV charging also includes the type of charging stations. The need for Rapid chargers at convenient locations is essential for any journey; as we know any type of rechargeable battery requires charging over long period of times, EV’s are no different. The smallest EV batteries are around 20-30kW and the largest can be up to 100kW. With a battery capacity around 100kW a standard 240V household plug socket would charge the battery in around 24 hours at 2.3kW. A specialised wall box charging point would charge the battery in around 7.5 hours at 7.4kW and a Rapid charger can charge a battery in under 1 hour, rated at 50kW. The availability of Rapid chargers is essential for most drivers traveling long distances otherwise the whole infrastructure would be deemed impractical.
In reality most EV owners will have a dedicated charger in the home connected to the internal household electricity supply and charge the vehicle overnight when electricity is much cheaper and there is less demand. These home chargers are either a standard 240V 13A socket or most energy suppliers will now install a wall unit that is 7.4kW/32A.
EV Charging pyramid
The growth of the EV market with car manufactures haw led to a variety of proprietary chargers and connection types, with each offering there own unique design. This single topic is a huge challenge within the overall design infrastructure for EV charging. One of the solution to this problem is the charging strategies.
At the lower end of the scale are slow chargers, which are typically rated between 2-3kW and can be used in almost any home. In addition to this there are also a number of home wall chargers that can be fitted outside your house or in the garage and these wall chargers are rated at 7.4kW and are directly wired up to the ring mains.
Fast chargers are found in most public spaces, such as car parks, shopping centres and some cases can be found in public street parking. These chargers will charge your EV at a particular rate as per the charging network. Fast chargers are rated between 7-22kW and can charge your vehicle from zero to full capacity in around 3-6 hours depending on your EV battery capacity.
Rapid chargers are even quicker and most commonly found in car parks, where EVs are left for few hours. They come in two types, AC chargers use 43kW of power and DC chargers 50kW. The DC chargers supply power direct to the car without any AC/DC power conversion and power loss in the process. With both of these charging methods an EV would charge its battery in around 1 hour.
At the top of the EV charging scale are superchargers, which charge anywhere between 120kW to 300kW. Tesla was one of the first EV car companies to design a supercharger at 120kW through its own proprietary connector and recently they announced a new supercharger at 250kW. Tesla claims it can fully charge its batteries in 15-30 mins across its network of over 20,000 superchargers in Europe. These type of chargers are ideal for service stations and gas stations as they are usually situated in ideal locations for long journeys and be easily accessible.
There are a few EV charging companies that have exceeded the 150kW that is commonly found with most superchargers. One of those companies is Swiss based ABB. ABB has launched its Terra high power DC fast charger, which can output up to 350kW, which is nearly three times the rate of Tesla’s superchargers. Unfortunately there is nothing in the market that can handle this type of charging ability, but the technology is there and is ready to be implemented for when EV’s have this capability.
Connectivity options
Not only are there a number of charging options within the EV infrastructure but there are also a variety of charging connectors. Each connector and charging system is incompatible with one another, which prevents a challenge within the EV industry. Here is a list of the most common types of EV connectors:
ype 1 plug – The type 1 plug is a single-phase plug which allows for charging power levels of up to 7.4 kW (230 V, 32 A). The standard is mainly used in car models from the Asian region, and is rare in Europe, which is why there are very few public type 1 charging stations.
Type 2 plug – The triple-phase plug’s main area of distribution is Europe, and is considered to be the standard model. In private spaces, charging power levels of up to 22 kW are common, while charging power levels of up to 43 kW (400 V, 63 A, AC) can be used at public charging stations. Most public charging stations are equipped with a type 2 socket. All mode 3 charging cables can be used with this, and electric cars can be charged with both type 1 and type 2 plugs. All mode 3 cables on the sides of charging stations have so-called Mennekes plugs (type 2).
Combination Plugs (Combined Charging System, or CCS) – The CCS plug is an enhanced version of the type 2 plug, with two additional power contacts for the purposes of quick charging, and supports AC and DC charging power levels (alternating and direct current charging power levels) of up to 170 kW. In practice, the value is usually around 50 kW.
CHAdeMO plug – This quick charging system was developed in Japan, and allows for charging capacities up to 50 kW at the appropriate public charging stations. The following manufacturers offer electric cars which are compatible with the CHAdeMO plug: BD Otomotive, Citroën, Honda, Kia, Mazda, Mitsubishi, Nissan, Peugeot, Subaru, Tesla (with adaptor) and Toyota.
Tesla Supercharger – For its supercharger, Tesla uses a modified version of the type 2 Mennekes plug. This allows for the Model S to recharge to 80% within 30 minutes. Tesla offers charging to its customers for free. To date it has not been possible for other makes of car to be charged with Tesla superchargers.
Home Charging Domestic socket – charging power levels of up to 3.7 kW (230 V, 16 A) can be reached with a domestic socket with the appropriate fusing. Your electric car will be charged via a mode 2 charging cable. We would definitely recommend a maximum charging power of 2.3 kW (230 V, 10 A) if the socket has not been checked beforehand. Domestic sockets can also sometimes be found at public charging stations. This charging method is available for all electric cars.
Designing Efficient and Future-Ready EV Charging Stations: Key Considerations
With the rising demand for electric vehicles, designing efficient EV charging stations is crucial. They must address challenges like communication, safety, security, and future grid integration while allowing for easy upgrades and incorporating essential components.
There was a time when electric vehicles were a rarity on the road, and technology seemed foreign to us. However, with the Rapid technological advancements, the buzz around electric vehicles grew, leading to the launch of numerous EV models by automotive manufacturers. As the demand for electric vehicles continues to rise, the need for better designed EV charging stations becomes increasingly important. Infact, in 2022, the global count of public charging points reached 2.7 million, with over 900,000 installations occurring during that year alone. This represents a substantial 55% increase compared to 2021’s figures.
Now it’s important to note that the new charging stations that are planted or will be planted are designed in a particular manner that they can accommodate quickly evolving EV charging ecosystem.
Designing an EV charging station presents a set of distinct challenges that need to be addressed. The electric vehicle supply equipment (EVSE) must effectively incorporate communication, safety, and security features while also considering the potential for future grid integration. It is crucial for the charging station design to provide a seamless upgrade path, allowing for easy adaptation to emerging technologies and evolving grid infrastructure requirements. Balancing these requirements ensures that the charging station not only meets the immediate needs of electric vehicle owners but also remains compatible and efficient as the electric vehicle landscape continues to evolve.
Let Us First Understand the Components That Make Up an EV Charger Design
EV charging station designs utilize a multitude of components, as it is not a one-size-fits-all approach. While charging stations installed at homes and petrol stations may differ in their specific configurations, they share many common components. Ensuring the use of effective components is of paramount importance to create a user-friendly, efficient, and visually appealing charging station.
Here is a comprehensive list of the components commonly employed in EV charging station designs:
Dual Color Beacons
Dual-color beacons serve as visual indicators of the status of an EV charging station. These beacons utilize colors such as green or red to convey information about the battery charge level or the availability of the EV charger. For instance, a green light may indicate a sufficient charge or availability for use, while a red light may signify a low charge or unavailability.
Cable Entry Systems
Cable entry systems are used in confined spaces to manage cables and pipes. These pre-assembled components find application in charging stations and power distribution panels.
Heaters and Fans
Heaters and fans are essential components in EV charging station design, chosen based on factors like station size, location, and type. These components play a crucial role in maintaining optimal temperatures, preventing damage from low temperatures and condensation.
Terminal Rails
Terminal rails serve as protective measures in electric vehicle stations, ensuring safety for other components within the system. Their incorporation into the electrical control system is imperative, making them an essential part of the overall setup.
EMC Cable Glands
EMC cable glands are crucial components found in EV charging stations, responsible for safeguarding supply and signaling cables. Their role is to prevent external interference that could disrupt the station’s electronics and communication. These glands ensure a stable and reliable connection to the cable screen.
Enclosures
Enclosures play a vital role in protecting the electrical components within an electric vehicle charging station from external elements. They also ensure the safety of users. Opting for high-quality and durable enclosures can not only enhance the aesthetics of the charging station but also allow for customization to fit specific brand requirements.
eInfochips has successfully developed an EV charging management platform for a client seeking remote control and monitoring capabilities for their residential and commercial fleet of EV chargers. The client desired an OCCP-compliant charging management system.
To learn more about this case study, please check – EV Charging Management Platform Development.
Design Recommendations for EV Charging Stations
Charging an EV fully at a public station takes an average of 1 hour and 17 minutes, highlighting the significance of efficient charging infrastructure that is also safe.
Safety- The primary concern in electric vehicle technology is safety, especially considering that charging stations operate at voltages higher than 120V in residential settings. When it comes to DC charging, there is a heightened risk of electric shock, as it can reach levels between 400V and 1000V. Electric shock may occur due to accidental contact with conductors and grounding. Insulation breakdown, caused by dust or moisture on the circuit, can contribute to this issue. However, the installation of a ground-fault protection device can prevent such incidents. This device safeguards drivers from electrocution in case of a damaged 1000-volt charging nozzle. When it detects an earth leak, it automatically cuts off power to the output side, ensuring the safety of the user.
Efficiency- Carbon emissions were the main driving factor behind the transition from fossil fuel-powered vehicles to electric vehicles (EVs). In addition to reducing emissions, EVs offer improved efficiency and overall performance. However, to fully capitalize on this technology, it is crucial to have proper infrastructure and a well-organized charging station solution. Without these elements, the potential benefits can be wasted. One might question why an EV owner would bother going to a charging station when they can achieve the same charging speed at home. The answer lies in the time it takes to charge at home, which typically occurs overnight. DC charging stations, on the other hand, can significantly expedite the charging process for EVs. By minimizing power conversion losses, these stations deliver the maximum amount of power to the vehicle batteries, resulting in much faster charging speeds.
Reliability- Installing a DC charger represents a significant commitment and investment. It is crucial to ensure that these chargers are built to withstand even severe weather conditions and have a long lifespan. The key to addressing reliability concerns lies in using high-quality components in the equipment and implementing protective measures. For instance, incorporating fuses that safeguard power converters from overcurrent can enhance the overall reliability of the charging system.
Grid Integration- Future EVs serve as both energy consumers and potential energy sources, supplying stored energy back to the grid during high demand or power disruptions. Robust communication systems in EV charging stations are crucial for seamless data exchange between the vehicle, the grid, and the Cloud while ensuring safety and security. The International Organization for Standardization (ISO) 15118 standard establishes a bidirectional communication protocol, enabling vital information exchange for car identification, charge control, and status. Adhering to ISO 15118 standards ensures compliance and long-term design adaptability for grid integration.
over, determining the ideal connectivity solution for EV chargers involves considering the use case, installation environment, and grid integration. Commercial chargers require Cloud connectivity for billing and data insights, while residential chargers should integrate with existing networks in Smart homes.
The Open Charge Point Protocol (OCPP) is the communication standard for charging stations and networks, supporting data exchange via Ethernet, cellular, Wi-Fi®, or Sub-1 GHz signals.
To meet OCPP flexibility requirements, chargers should offer diverse connectivity options. Wi-Fi enables integration with infrastructure or local connectivity, while Sub-1 GHz is reliable in challenging RF environments. Flexibility is crucial for commercial or residential chargers, ensuring stable connections and interoperability with networks, even in harsh conditions.
Final Thoughts
The EV charging industry is undoubtedly progressing, becoming more systemized, Smart, and efficient. To truly benefit consumers, continuous upgrades and a customer-centric approach are essential in the design process. The charging station’s design plays a crucial role in shaping the overall customer experience and contributes significantly to the evolving EV industry.
As the demand for EVs continues to rise, the need for a suitable charging infrastructure becomes increasingly important. eInfochips has successfully assisted one of its clients in providing EV charging solutions for both residential and commercial segments. In response to the growing market demands, eInfochips helped the client upgrade their existing product line. To learn more about how eInfochips helped overcome this challenge, you can read the full case study here –
eInfochips has extensive experience in developing next-generation EV charging solutions for leading customers, resulting in award-winning products. In addition to designing and manufacturing EV charging hardware, we specialize in developing mobile/web apps, IoT management platforms, and IoT/Cloud-enabled management platforms. To explore our range of key offerings and services, you can find more information here. If you would like to get in touch with our team of experts, please click here to contact us.
Pooja Kanwar
Pooja Kanwar is part of the content team. She has more than two years of experience in content writing. She creates content related to digital transformation technologies including IoT, Robotic Process Automation, and Cloud. She holds a Bachelor of Business Administration (BBA Hons) Degree in Marketing.
Driverless Cars – Shifting Customer Experience into High Gear
Electric vehicle charging level standards
As the EV world currently operates, there are three levels to charging your vehicle based on varying speed and power. The tier system starts with the lowest charging at Level 1 and gets faster from there.
These levels are important to understand as they each offer pros and cons. Furthermore, each will be preferential at some point given your driving circumstances on a given day.
Level 1 – 120V chargers
Think of Level 1 as a universal charging option. If there is a wall socket nearby, you will be able to charge your EV without issue. A 120V socket and 15 amps remains the standard electrical outlet in North America, although you’re probably looking at more like 12 amps for a continuous load after de-rating your breaker.
Still following? Either way, it shouldn’t be too tough to find a plug in any home or garage, which is nice.
With that said, 110-120V is the bare minimum amount of juice you can pull into your EV. As a result, recharge times trickle at a rate of 3 to 5 miles of range per hour, based on the 1.4 kW power the average 120V wall socket supplies at 12 amps. So if the battery capacity of your 2021 Mustang Mach-E is 88kWh, you’re looking at days to charge, not hours. Nearly 63 hours by our count.
Level 3 – DC Rapid/fast/Superchargers
The name may vary, but the process is the same. For the sake of explanation, let’s refer to them as DC fast chargers (DCFCs). These Level 3 chargers abandon the alternating current (AC) methods above to mainline power directly from the grid. While they require a lot more power (480 volts and 100 amps), their output is truly “super.”
DC fast chargers can offer 50-350 kW of power; some in Europe are even reaching 400 kW. Depending on the power available, a Level 3 charger can fully replenish your EV in twenty to thirty minutes. This type of charging is ideal for roadside stops, or retail where you may not be parked for too long or need to get back on the road.
Hyundai’s Ioniq 5 charged from 22% to 80% in just 16 minutes, so these fast charge numbers grow quicker by the day. It’s important to note that not all EVs are currently equipped for DC fast charging, although most all new EVs hitting roads do.
If that is the case for you, there are plenty of public charging stations that offer Level 2 power.
Electric vehicle charging standards for connectors
Now that we’ve covered the levels you can choose from when charging, we will FOCUS on the equipment you may encounter. These charging connectors vary by electric vehicle and are separated into two categories – The standard Level 1 and Level 2 connector, and DC fast charging connectors. Here’s how they differ.
SAE J1772
This connector is the industry standard for all electric vehicles performing Level 1 or Level 2 charging. Whether it’s the cord provided with the purchase of your EV or the Level 2 charger outside of Whole Foods, the J1772 is going to connect.
CHAdeMO
This is the first of three types of connectors currently present on EVs and first introduced. Originally it was implemented to be the industry standard, developed through the collaboration of five different Japanese automakers.
As a result, the CHAdeMO connector remains affluent in Japan and on EVs from Japanese manufacturers. This includes automakers such as Toyota, Mitsubishi, Subaru, and Nissan.
CCS
Shortly after the CHAdeMO was introduced, a second connector called the Combined Charging System (CCS) was implemented as an additional charging standard.
Where CCS connectors differ from CHAdeMO, is that they allow for AC/DC charging on the same port. CHAdeMO-equipped EVs require an additional J1772 connector cord to achieve Level 1 or 2 charging.
This connector is the preferred mode of charging amongst European and American automakers, including BMW, Ford, Jaguar, GM, Polestar, Volkswagen, and even Tesla. Additionally, CCS is will be present on the upcoming Rivian EVs.
Tesla Supercharger
From day one, Tesla has chosen to pave its own way in the EV industry, and that is no different with its Supercharger connector. This proprietary connector exists on all Tesla models in North America, although it does offer CHAdeMO and CCS adapter for certain markets.
For example, its Model 3 was built with a CCS connector for Europe. Furthermore, older European Teslas were retrofitted with adapters to support the existing connector plus the standard CCS type 2. This helped Tesla owners utilize the growing charger network overseas.
Even after testing the connector adapter in the Korean market last December, Tesla has yet to bring it to North American drivers. Last month, however, EVgo announced it would be bringing Tesla compatible connectors to over 600 of its US charging stations. Regardless of the other connectors and their compatibility, Tesla’s Supercharger network already features over 20,000 charging stalls at over 2,100 stations around the world.
Most recently, Tesla CEO Elon Musk has shared that the American automaker will begin sharing its EV network with other EVs later in 2021.
For more detailed information, check out our Tesla Supercharger guide.
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Take advantage of EV incentives
Governments and local utilities offer a wide range of tax credits, rebates, and grants to make EV charging more affordable. ChargePoint makes it really easy to find out which incentives are available to you.
The U.S. Department of Energy has a site called Alternative Fuels Data Center that lets you search for information about EV incentives.
Enel X also has a comprehensive database of EV tax credits, rebates, and incentives (federal and state). Just enter your zip code or click on your state to learn more.
Investing in a greener future is more affordable than you think. Do your research and save.
Design and upgrade ideas for garages with EV chargers
Adding an EV charger to your garage will change how it looks and functions to a certain degree. Indoor parking will be a priority (as it should be. that’s what a garage is for, right?), so good organization is essential.
Even though they occupy a relatively small amount of the room’s space, some homeowners may think the sight of a wall-mounted charger and hanging cable negatively impacts the garage’s aesthetic. That’s a valid concern, especially for homeowners who have chosen a specific décor for their garage or are planning to do a major remodel soon.
Garage Living is capable of designing customized cabinets that can hide an EV charger system and its accessories and still keep it easily accessible. This helps the garage look tidier and provides you with additional storage options.
We’ve fulfilled similar requests on previous remodel projects from customers who wanted unsightly utility features like electrical panels, central vac systems, elevator systems, and more hidden away.
If you’re planning on an upgrade of your garage interior at the same time you’re adding an EV charging station, our ReCHARGE garage design theme may be just right for you. The exclusive theme from our Designer Series features a neutral color palette comprised of nature-inspired shades. This creates a clean, refreshing look that pairs beautifully with an EV home setup.
You’ll want to park your new EV on something nicer than a dusty, cracked, and grey floor. Transform it to make it look as modern as your new ride with a Floortex™ floor coating application.
Finally, it’s worth investing in insulation upgrades for your garage if the room is lacking in that department. Adding wall and ceiling insulation is another impactful way to make your home more energy-efficient and helps you save on your utility costs, too.
Parking EVs in an insulated space also helps the charging process and batteries function more efficiently in extreme cold temperatures.
Is your garage EV-ready?
If you own an EV or are planning to buy one, you’re clearly a forward-thinking person who enjoys being a leader, not a follower.
It’s this type of discerning individual who recognizes that their garage doesn’t have to look like most garages do – dull, outdated, lacking any style, and perpetually disorganized.
The future is now. Is your garage ready for it?
Schedule a free design consultation with us to start getting your garage EV-ready.
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