Defining and Developing Standards

Peter Van den BosscheSecretary of IEC TC69

Erasmus University College Brussels

Vrije Universiteit Brussel

1

P. Van den Bossche

EV Standardization

❖The electrically propelled vehicle

❖ Is it a Vehicle?

❖ Is it an Electrical Device?

2

P. Van den Bossche

Main Actors

❖ International Electrotechnical Commission

❖ Electrical standards

❖ Founded 1906

❖ IEC TC69

❖ International Organization for Standardization

❖General standards, including road vehicles

❖ Founded 1948

❖ ISO TC22 SC21

3

P. Van den Bossche

A Chequered Past

❖Specific EV standardization work

❖ Started around 1970 in the global committees

❖Conflict of competence domains

❖Who should do the work

❖ Background of committees

❖Differences in standardization culture

❖Automotive

❖ Electrotechnical

4

P. Van den Bossche

Division of labour

❖ ISO/IEC steering committee

❖Outstanding issues

ISO TC22 SC21 IEC TC69 Aspects related to the

electric vehicle as a whole Aspects related to electrical

components and electric supply infrastructure

5

P. Van den Bossche

Charging infrastructure at IEC TC69

❖ IEC TC69 has been dormant for a number of years, but has now started the revision of the IEC 61851 conductive charging standard

❖ Part 1: General requirements

❖ Part 21: Electric vehicle requirements

❖ Part 22: a.c. charging station requirements

❖ Part 23: d.c. charging station requirements

❖ Part 24: communication protocol

6

P. Van den Bossche

The battle of the modes

❖Mode 1 charging: non-dedicated outlet

❖Mode 2 charging: non-dedicated outlet with in-cable protection device

❖Mode 3 charging: dedicated outlet

❖Mode 4 charging: d.c. connection

7

P. Van den Bossche 8

Mode 1 charge

❖Use of standard, non-dedicated socket-outlets

❖Earthing and GFCI are essential for safety

❖ Compulsory in all new electric installations

❖Not guaranteed in legacy installations

❖Not allowed in certain countries

❖Most widely used system today

P. Van den Bossche

Dangerous condition without earthing

9

P. Van den Bossche 10

Mode 2 charge

❖Use of standard socket-outlets

❖ In-cable or in-plug protection box with pilot

function

❖Transitory solution in USA

P. Van den Bossche 11

Mode 3 charge

❖Dedicated socket-outlet for EV use

❖Protection with control pilot function

❖Power levels:

❖ 16 A: “normal” charging

❖ 32 A: “semi-fast” charging

❖High power - “fast” charging

P. Van den Bossche 12

Mode 3: Control pilot function

❖Verification of correct connection

❖Socket is dead if no vehicle is present

❖ Integrity of earthing

❖Ampacity of charger

❖Essential for public infrastructure

P. Van den Bossche

Control pilot implementation

❖ IEC 61851 (2001) requires a hard-wired physical control pilot conductor

❖ Extra wire

❖ Impedance R between pilot and earthing: 1000 Ω

❖ Current through loop pilot-earth

❖ Breaking the current loop breaks the circuit

13

P. Van den Bossche

Hard-wired pilot conductor (example)

14

P. Van den Bossche

New developments

❖ Revision of IEC 61851 replaces “control pilot conductor” by “control pilot function”

❖ Same functionalities

❖ Example: use of carrier line signal between charging post and vehicle

❖No extra conductor: use standard accessories

❖ Compatibility of modes:

❖Mode 3 for public charging posts

❖Mode 1 for charging on private premises

15

P. Van den Bossche

Mode 3 fast charge

❖Charging via traction inverter

16

P. Van den Bossche

Mode 3 fast charge

❖No heavy off-board charger needed

❖Opportunities for bidirectional working

❖ Peak-shaving

❖Grid management

17

P. Van den Bossche 18

Mode 4 charge

❖Stationary charger

❖d.c. connection

❖Heavy and expensive infrastructure

❖Standard IEC 61851-23 not

published (stuck at CD level) but will

be treated with the ongoing revision

P. Van den Bossche

Accessories

❖Wall side: plug and socket-outlet

❖ socket-outlet

❖ plug

❖Vehicle side: vehicle coupler

❖ vehicle connector

❖ vehicle inlet

19

P. Van den Bossche

Parts of the conductive connection

20

P. Van den Bossche

Case A: cable fixed to the vehicle

21

P. Van den Bossche

Case B: separate cable

22

P. Van den Bossche

Case C: cable fixed to charging post

23

P. Van den Bossche

Plugs and sockets

❖Mode 1: use of standard plugs and sockets

❖Compatibility with Mode 3 can be obtained

❖Standard plugs:

❖ domestic types

❖ industrial types

24

P. Van den Bossche

Domestic Accessories

❖Domestic accessories are not suited for EV duties

❖ Long-term full load current

❖Disconnection under load

❖Mechanical stress

❖ Environmental stress

25

P. Van den Bossche

Industrial plug standards

❖ IEC 60309

❖ IEC 60309-1: general requirements

❖ IEC 60309-2: dimensional requirements

26

P. Van den Bossche

IEC 60309-2 plugs

❖ International standard product

❖Reliable

❖Cheap

❖Well suitable for EV use in Mode 1

❖Also for Mode 3 (without physical pilot)

27

P. Van den Bossche

Dedicated EV accessories

❖Standardization work IEC SC23H

❖ IEC 62196-1:2004 - Plugs, socket-outlets, vehicle couplers and vehicle inlets - Conductive charging of electric vehicles

❖ Based on the definitions of IEC 61851

❖ Functional requirements based on IEC 60309-1

❖ Physical control pilot

❖No dimensional definitions

❖Up for revision

❖Examples of dedicated EV plugs

28

P. Van den Bossche

Framatome plug

❖Used by EDF in France

❖Predates SC23H work

❖Extra pin voor pilot

❖Compatible in Mode 1with standardFrench/Belgian socket

❖Expensive

❖Poor reliability

29

P. Van den Bossche

Scame plug

❖Extra pin for pilot

❖Rated 16 A in mode 1

❖Rated 32 A in mode 3

❖Conforms to IEC 60309-1

❖ Reliability of an industrial plug

❖Non compatible with IEC 60309-2 or with domestic plugs

❖National Italian standard

30

P. Van den Bossche

Mennekes plug

❖Modified IEC 60309-2 design

❖Complies to IEC 60309-1

❖Lateral contact for pilot

❖Rated 16 A in mode 1

❖ compatible with standard IEC60309-2 socket

❖Rated 32 A in mode 3

❖with special socket

❖Used in Switzerland

31

P. Van den Bossche

Vehicle Coupler Design Constraints

❖Accomodate high and low power charging

❖Vehicle real estate

❖Reliability and Safety

❖Cost

❖ IEC61851 solution is very complicated

❖Rationalization due with revision

32

P. Van den Bossche

Definitons of IEC 61851

33

The electric vehicle - raising the standards

!"#

Position Universal Basic FunctionsHigh power

a.c./a.c.High power

d.c./a.c.Domestic

a.c.a.c.

UA UD U$% B! &'' V %&' A #'' V ('' A - - High power

d.c./a.c.% &'' V %&' A #'' V ('' A - - High power

d.c./a.c$ &'' V %&' A - - - High power a.c.

( ('' V $% A ('' V $% A ('' V $% A ('' V $% A L!

& ('' V $% A ('' V $% A ('' V $% A ('' V $% A L%

# ('' V $% A ('' V $% A ('' V $% A ('' V $% A L$

" ('' V $% A ('' V $% A ('' V $% A ('' V $% A Neutral

) Rated for fault Rated for fault Rated for fault Rated for fault PE* $' V % A $' V % A $' V % A $' V % A Control pilot

!' $' V % A $' V % A $' V % A - Communication !(+)

!! $' V % A $' V % A $' V % A - Communication %(-)

!% $' V % A $' V % A $' V % A - Clean data earth

!$ - - - $' V % A Power indicator!( - - - $' V % A Power indicator

Table !.": Overview of the vehicle interface requirements&('

The design of the interface did grow with the other specifications in the developingstandard document to eventually evolve to two designs at the vehicle interface&(!:!! A “universal” interface which provides for all modes of charging. It features

“domestic” a.c. connection (up to $% A), and either high power a.c., or highpower d.c., since it is deemed unlikely that these two would be used at the sametime. The universal interface contains up to !% contacts, which may be used ornot: one may have a high-power connector, featuring either a.c. or d.c. highpower, as well as domestic a.c. contacts, or a “domestic” connector, featuringonly domestic a.c. contacts. The universal vehicle inlet shall be intermateable&(%

with either the high power a.c. connector or the high power d.c. connector. Bothtypes of vehicle inlet shall be intermateable with the domestic a.c. connector.The ratings of the contacts are shown in Table &.$. Lower current values areavailable.

!! A “basic” interface, for modes !, % and $ charging only, providing for“domestic” a.c. connection only, single-phase or three-phase. This consists alower cost solution for vehicles which do not require fast charging. The “basic”vehicle inlet shall be intermateable with either the single-phase or the three-phase“basic” connector. It shall not be intermateable with accessories of the universalinterface type. Ratings are shown in Table &.$. Lower current values (e.g.!# A) are available.

&(' +,- #!)&!-!:%''!, Table +&(! Ibid., ¶).!&(% “Intermateability: the ability of like accessories to join together with the mating accessories they areintended to be used with” (+,- #%!*#⁄-./, ¶%.!#)

P. Van den Bossche

Vehicle connector

❖1990s designs:

❖AVCON (US)

❖Maréchal (F)

❖Common vehicle inlet for normal or fast charging

❖Connectors in light and heavy version

34

P. Van den Bossche

New proposal for standard coupler

❖New work item proposal for IEC SC23H initiated by Japan

❖ IEC 62196 Part 2: Dimensional interchangeability requirements for pin and contact-tube vehicle couplers

❖Rated 230V, 30A

❖“Basic” interface as to IEC61851-1

35

P. Van den Bossche

New proposal for vehicle connector

❖Single phase power

❖Earth

❖2 signal contacts

36

P. Van den Bossche

Battery connectors

❖Used for industrial vehicles

❖Used as internal connector

❖Not for operation under load

❖Not suitable for consumers

37

P. Van den Bossche

The first ever EV standard (1913)

38

P. Van den Bossche

The first international EV standard

❖British Standard BS74

39

P. Van den Bossche

Regional standardization

❖Europe

❖Activities in CENELEC TC69X transferred to IEC level

❖USA

❖ SAE standardization

❖Japan

❖ JARI standardization

40

P. Van den Bossche

Conclusions

❖Benefits of International Standardization

❖Use of Standard Industrial Plugs

❖Mode 3 charging at public premises

❖Mode 1 charging at private premises

❖Benefits of Standardized Vehicle Couplers

❖ International Collaboration

❖Avoidance of Conflict

❖Avoidance of Double Work

41