future generation for dc fast charging systems€¦ · • proprietary solutions for fast charging...

IAV 02/2017 UWt VT-E Vertraulich/Confidential

Future Generation for DC Fast Charging Systems

14. Braunschweiger Symposium Hybrid- und Elektrofahrzeuge

Ursel Willrett, Braunschweig, February 2017

1

Contents – DC Fast Charging Systems


Motivation

DC Charging Systems

Challenges for fast charging

systems

Approach for solutions

Summary

2

Status Quo „Charging connector“

IAV 02/2017 UWt VT-E Vertraulich/Confidential 3

Type 2 CCS CHAdeMO GB/T 20234

AC-Charger DC-Charger DC-Charger DC-Charger

Umax = 400 V,

3-phase

Umax = 850 V Umax = 600 V Umax = 750 V

Imax = 63 A Imax = 200 A Imax = 200 A Imax = 250 A

PConnector = 43,5 kW PConnector = 170 kW PConnector = 120 kW PConnector = 187,5 kW

Communication = PWM/PLC Communication = CAN


Tesla Supercharger

Tesla Super Charger (Power 120kW) Requires a proprietary connections only compatible with Tesla vehicles.Battery energies: 60 kWh .. 90 kWh

The Supercharger charges the batteries• In 30 minutes up to 50% SOC• in 45 minutes up to 80 % SOC • in 90 minutes battery completely charged

Source: www.teslamotors.com/de_AT/supercharger

Range (km)(30 minutes load time)

Load times


Minimal Standard Comfort

230V / 16A1 Phase

400V / 16A3 Phases

t = 8 h t = 3 h t = 2,0 h

400V / 32A3 Phases

P = 3,3 kW P = 11 kW P = 22 kW

Capacity of battery = 25 kWh, load time = Capacity of battery / charging power

AC Fast Charging

400V / 63A3 Phases

t = 1 h

P = 43,5 kW

DC Fast Charging

400V / 125ADC

t = 0,75 h

P = 50 kW

Charging Infrastructure – the next level

6IAV 02/2017 UWt VT-E Vertraulich/Confidential

Source: 19. Internationaler Fachkongress „Fortschritte in der Automobil-Elektronik“, Ludwigsburg, 23./24. Juni 2015


DC Charging System – Power supply

Performance of Power Supply relates on:

• Power supply access:

• low voltage

• medium voltage

• DC voltage access (i.e. electric tramway)

• Available nominal power (kW)

• Available power (kW) at a given time (load management, Smart Grid)

Plug EVCase CDC DC

DC Charging Station

Power supply Charging Station Load cable Electric vehicle


DC Charging System – Charging Station

Performance of charging station relates on:

• Maximum input power

• Technical conditions, i.e. size, weight, temperature control

• International standards (IEC 61851) specify 1000V, 200A maximum for output power of the charging station

Source: IAV

Plug EVCase CDC DC

DC Charging Station



DC Charging System – Load cable

Performance of load cable relates on:

• Technical conditions, i.e. size, weight, maximum temperature of the connectors

• International standards (IEC 62196) specify 850V, 200A maximum for power of the load cable

Source: www.phoenixcontact.de

Plug EVCase CDC DC

DC Charging Station



DC Charging System – Electric vehicle

M

High voltage battery

• Technical conditions: number of cells, connections of the cells -> (V,I), size, weight

• Battery technology

Power electronic unit, electric engine

• Technical conditions: (V,I), size, weight

Harness, connectors, fuses, contactors, sensors

• Technical conditions: (V,I), size, weight

• Availability of the components related on selected (V,I) for automotive conditions

11

Load times - Relations

Load time: � = �

�

Power [kW] Load time [min]

50 24

170 7W=20 kWh

� = � ∗ �

Power Loss ?

Maximum Voltage?

Maximum Current?

Maximum Weight?

Maximum Size?

Medium voltage access – example Tesla Supercharger


Medium voltage access(15kV)

Transformer(P up to 1MVA)

TeslaSuperchargerDistribution/

SafetyTesla

Charging Tower

L1

L2

L3

N

PE


High power charging station - Example



Power: 45 / 90 / 150 kW

Voltage: 50 to 920 V (1.000 V)

Current: 0 to 200 A

Communication: IEC61851-23

PLC (CCS / Combo-2)

Connector: Combo T2

(CCS / Combo-2)

Dimensions: 1000 x 800 x 1800 mm

(at 150 kW)

Source: electricmobility.efacec.com/ev-qcbus

Load Cable – Fast Charging up to 350A


• The available standards provide 200A charging current at 850V charging voltage without cooling. (IEC 62196-3)

• The proposed extension in the charging plug with the cooling circuit the max. charging current increases to 350A.

• Requirement of the standard, dT <=50K, is full-filled with the solution.

• Charging power of more then 300kW for the load cable is achievable.


Source: www.phoenixcontact.de

HV-Battery Storage


• The total HV-battery voltage Vbatt is given by the number of cells in series.

• The maximum charging current is determined by the number of parallel circuits.

• The maximum current for each circuit is limited by the cell parameter (maximum current).

• Charging power P is equal to the product of V and I.

• Charging with high power impacts the life time of the battery.

HV-Battery, p parallel parts

S cells in series

Vbatt

I

�� = �� ∗ ��

� � = �

�� =

�� ∗ � ∗ �

� ∗ �� ∗ � ∗ �� =

��

�� ∗ ��

Using cell parameters from the data sheet of the selected cell the minimum achievable load time of the HV-battery is calculated by:


W: battery capacityWz: cell capacityS: number of cells in seriesP: number of cells parallelVz: voltage of cell Iz: maximum continuous current of the cell

Estimation of power loss of a 400V HV-Battery during charging process


�� = � ∗�

��+ ��

�� = � ∗(�� − ��)

��

� = �

�

Source: IAV


Performance related to use cases

Use Case Batteryconnection

Max.continuoscharg. current

Max. Batteryvoltage

Max. chargingpower

Power loss

Batterymass

Range Load time90%

Load time100 km

Available EV 90s 3p 120 A 350 V 42 kW 0,78 kW 318 kg 130 km 30 min 20 min

Increased

charging current

90s 3p 200 A 350 V 70 kW 2,16 kW 318 kg 130 km 18 min 12 min

Max. battery size

(medium size

passenger car)

220s 2p 180 A 855 V 154 kW 6,52 kW 527 kg 191 km 14 min 5,49 min

Power optimized

cell

354s 2p 250 A 1380,5 V 358,2 kW 20,34 kW 850 kg 265 km 10,5 min 2,54 min

1. Available electric vehicle, medium size passenger car

2. Available electric vehicle, increased charging current

3. Battery increased to the maximum regarding size and weight (based on medium sizepassenger car)

4. Charging with 350 kW


Maximal charging power >170 kW

• Extensions of existing standards required (i.e. IEC 61851, IEC 62196)

• All components of the fast charging system can be extended to provide the respective performance features.

• Proprietary solutions for fast charging systems can be used by a sub-set of users only -> therefore they are not appropriate to ensure long-term business success

• Intelligent upgrading is performed -> DC fast charging only if required!

Plug EVCase CDC DC

DC Charging Station


Summary and Prospect


• Available international standards already enable development of DC fast charging up to 170 kW.

• Fast charging systems today perform charging power up to 60kW with standardized solutions, Tesla Super Charger provides 120kW.

• Technical extension to charging power until 170kW and beyond is feasible with existing technologies:

– Power supply: Medium voltage access

– Charging station: high power fast DC Charger

– Load Cable: connectors, cooling features

– Electric vehicle: HV-Battery increase, adaptation of HV vehicle components

• For proper roll-out of charging systems >170kW extensions of the international standards are required.

Future generations for DC Fast Charging Systems is feasible even with todays technologies .

Intelligent upgrade where needed according to user benefit and business case.

19

Thank You

Ursel WillrettInfrastructure Systems E-Mobility

Tel. +49 7031 [email protected]

www.iav.com


future generation for dc fast charging systems€¦ · • proprietary solutions for fast charging...

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