Combined Charging

Current status of the Combined Charging System

EPRI Infrastructure Working Council December 14, 2011

Jeanette Clute (Ford)Cliff Fietzek (BMW)George Bellino (GM)

V1.5

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)2

Current Status Charging ConnectorsVarious regional connectors should be migrated into one global solution

Regional, mutually incompatible connectors

1st Generation

Combined Charging System for global AC and DC charging

2nd Generation

Current_status_of_the_Combined_Charging_System_V1.0

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Benefits of Harmonization

Reduces infrastructure planning complexity and cost.

Provides a uniform standard reducing vehicle complexity and cost for global manufacturers.

Provides customers increased confidence for charging expediency and extended driving use cases.

Provides a uniform standard with identical electrical systems, charge controllers, safety mechanisms, and common sheet metal interface dimensions.

Clear market signal facilitates growth of public charging infrastructure.

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

EU and US Harmonization: Transatlantic Economic Council

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Global OEMs Agree on Harmonized Approach for US and EU

AUDI, BMW, DAIMLER, FORD, GENERAL MOTORS, PORSCHE and VOLKSWAGEN AGREED TO SUPPORT A HARMONIZED, SINGLE-PORT FAST CHARGING APPROACH FOR USE ON ELECTRIC VEHICLES IN EUROPE AND THE UNITED STATES.

Smart ForTwo EV Focus EV

Audi R8 e-tron VW Golf blue-e-motion

BMW i3 Spark EV

Porsche Boxster E

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Strategic Assessment of DC Charging Systems

6

7 OEMs have agreed to implement the combined charging systems.

Audi, BMW, Daimler, Ford, GM, Porsche and Volkswagen agreed on combined charging

One connector to support AC/DC chargingOne communication for AC/DC charging Homeplug GreenPhy

PLC communication between EV and EVSE to control DC charging and support integration into the smart grid.

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)Current_status_of_the_Combined_Charging_System_V1.0 7

SAE J1772 or IEC 62196-1 Type 1 for North America and JapanType 1 supports all infrastructure scenarios in North America, Japan and meets OEM requirements.

J1772 applicable for charging modes AC Level 1, AC Level 2

J1772 is provenintroduced to the market accepted by all major OEM’s and EVSE suppliers

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Combined Charging: Benefits

Addressing the needs of CONSUMERS and planting the seeds for a SMART future for vehicle electrification

AC and DC Fast Charging with One InletStandard Communications with the Charging StationLight WeightStandard Safety Mechanisms“State-of-the-Art” User Friendly Design

DC Fast Charging offers 80% charge in less than 15 min

It is the electric equivalent to a commercial fuel pump.

US TYPE 1 COMBOUS TYPE 1 COMBO

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

DC Charging: Customer Benefits

Current_status_of_the_Combined_Charging_System_V1.0

DC charging offers confidence in driving range and extends customers driving use cases due to its ability to charge faster.

DC charging satisfies customer expectations for fast and ultra-fast charging.

9

charging time5 min 15 min 30 min

30 mi

60 mi

90 mi

120 mi

20 kW

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)10

Charging Connectors for the Combined Charging SystemThe Combo inlet shall serve as a universal plug for all relevant charging scenarios.

AC-Level 2

DC-Level 2

Household socketAC Level 1

Current_status_of_the_Combined_Charging_System_V1.0

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Protective covers

High power DC charging via dedicated pins

Charging control communication with PLC

Current_status_of_the_Combined_Charging_System_V1.0 11

DC Combination Charging: Vehicle Inlet DesignThe DC Charging combination inlet provides comprehensive functionality at a high level of safety.

Diagnosable lock1

Proximity and control pilot

2

3

Safety features

1-phase AC charging with Type 11

3

4

Function

Integration into smart grid2

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Availability of Combo DC-ChargersSample chargers for the Combined Charging System are ready.

12Current_status_of_the_Combined_Charging_System_V1.0

Two-box design: charge pump and separate converterNetwork connection to AC 3ph 125A 480V Charging communication via PLC (HPGP)Charging connector DC Type 2Safety measures according to IEC 61851-23

Two sample vehicles with integration of DC Type 2 or Combo 2 Inlet respectivelyCharging current up to 70A DCAlternatively, charging with AC 1ph via the same inlet possibleVehicles used for permanent testsHandling with high comfortAcceptable temperature rise at connector

Charging Station

Vehicle

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Combined Charging System

Current_status_of_the_Combined_Charging_System_V1.0 13

Combined Charging: the universal charging system for electric vehicles has been demonstrated at vehicles of German OEMs at the 15th international conference on „Electronics in Vehicles“ at Baden-Baden on October 12-13.

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Availability of VehiclesPr

oduc

tion

vehi

cles

14

Vehicles have been announced and are under development.

Current_status_of_the_Combined_Charging_System_V1.0

VW E Up!

Smart ForTwo EV Focus EV Audi R8 e-tron VW Golf blue-e-motionBMW i3

Spark EV

Volt

Active E Ford CMAX Energi

Production vehicles with the combined charging system will be available in 2013.

Active E

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)Current_status_of_the_Combined_Charging_System_V1.0 15

Backup

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Comparison Combo 2 and separated Inlets

Combo 2 DC China + AC Type 2 China

16

Combo inlet optimizes charging and increases robustness.

General EV Charging System, V1.0

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)Current_status_of_the_Combined_Charging_System_V1.0 17

Design DC Combo 2 InletThe Combo 2 inlet provides comprehensive functionality at a high level of safety.

Diagnosable lock1

Proximity and control pilot2

Charging control communication with PLC

3

Safety features

1-phase AC charging with Type 21

DC charging with Type 23

3-phase AC charging with Type 24

Function

High power DC charging via dedicated pins

5

Integration into smart grid2

introduced to the market

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)Current_status_of_the_Combined_Charging_System_V1.0 18

Standardization of AC Connectors (IEC 62196-2)International Standardization defines 3 options for AC connectors. European Commission promotes the selection of one connector for Europe.

Type 1: 1-phase Type 2: 1- to 3-phase Type 3: 1- and 3-phase

One AC connector to be applied in Europe to ensure unrestricted mobilityNational regulations need to comply with overall decisionRule of subsidy does not apply due to cross-border traffic

(vehicle side only)

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Combined Charging Connector Concept

USA Europe

Connector

kW

AC3-phase

DC(Type 1 up to 36 kW)

5 kW 50 kW 100 kW

DC(Combo System)

AC1-phase

Application range

AC 1-phase plus

The Combo Connector Concept integrates the existing AC connectors into a single system, allowing for a single global vehicle interface for AC and DC.

19Current_status_of_the_Combined_Charging_System_V1.0

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)Current_status_of_the_Combined_Charging_System_V1.0 20

Design DC Combo InletIntegration of AC and DC into a single inlet provide high freedom for vehicle design. Mechanical dimensions of package are highly optimized.

Combo 2 Inlet for EuropeCombo 1 Inlet for US

Scale 1:2Scale 1:2

Combo Connector based on Type 1 and Type 2 have been jointly submitted to IEC by Germany and the US. Both Combo Connectors have identical package and fixation.

102

74

68

9419

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)

Charging Protocol defined by ISO/ IEC 15118DC Charging communication is standardized based on existing AC Charging communication.

IPv6 based protocolTransport layer with dedicated security measured Flexible XML-based messagesAC as well as DC messages

DC Charging and AC Charging use the same protocol stack

HomePlug GreenPhy on Control PilotUses GreenPhy StateLess Address AutoConfiguration for EV/EVSE Association Common Layer1 / Layer2 solution for AC and DC-Charging

ISO/IEC15118-3 focus on HomePlug GreenPhy as Layer 1 & Layer 2 solution

Layer 1 –Physical

Layer 2 –Data Link IEEE1901

HomePlugGreenPHY

Layer 3 –Network IPv6 (Internet Protocol)

Layer 4 –Transport

UDP (User Datagram Protocol)TCP (Transmission

Control Protocol)

TLS (Transport Layer Security 1.0)

Layer 6 –Presentation EXI – Efficient XML interchange

Layer 7 –Application

Smart Charge Protocol

(Application Layer + Session Layer)

SLAAC (Stateless Address

Autoconfiguration)

Optional: DHCP (Dyn. Host

Conf. Protocol)

Layer 5 –Session

V2GTP (Vehicle to Grid Transfer Protocol)

Optional: HTTP (Hypertext Transfer Protocol)

21Current_status_of_the_Combined_Charging_System_V1.0

Jeanette Clute (Ford)

Cliff Fietzek (BMW)

George Bellino (GM)22

Relevant Standards for the Charging InterfaceThe charging system is comprised by a set of related standards.

Connector

1

Communication

2

Charging topology

4

ISO/IEC 15118

IEC 61851-21

IEC 62196-1

Safety

3

IEC 60529

ISO 6469-3

SAE J2931SAE J2847

SAE J1766

IEC 62196-2IEC 62196-3

IEC 61850

IEC 61851-1IEC 60364-7-722

SAE J1772

IEC 61851-24

IEC 61851-22

IEC 61851-23

ISO 17409

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