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Report on the Current Situation and Future Direction of Electric Vehicle Charger Standardisation

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Report on the Current Situation and Future Direction of Electric Vehicle Charger Standardisation Report on the Current Situation and Future Direction of Electric Vehicle Charger Standardisation October 2009 July 2010 SMMT Report on the Current Situation and Future Direction of Contents Electric Vehicle Charger Standards, July 2010 Contents 1. Introduction................................................................................................ Page 1 1.1. Purpose of the study 1.2. Scope 2. Standards and Recommended Practices...................................................... Page 3 2.1. SAE (Society of Automotive Engineers) 2.2. IEC (The International Electrotechnical Commission) 2.3. Japan 3. Legal Requirements.................................................................................... Page 8 3.1. Europe 3.2. USA 4. ACEA Recommendations............................................................................ Page 10 5. Survey of Vehicle Manufacturers............................................................... Page 11 6. Charge Connector Suppliers...................................................................... Page 12 7. Charging Infrastructure............................................................................ Page 13 7.1. UK 7.2. Mainland Europe 7.3. US 8. Conclusions............................................................................................... Page 14 Appendices Appendix 1: European Vehicle Category Definitions Appendix 2: Diagram showing the Charge Connector Components Appendix 3: Definitions of Charging Modes and Charging Connection Cases from IEC 61851-1 Appendix 4: Examples of Electric Vehicle Charge Connectors Appendix 5: Summary of Charge Connector Ratings Appendix 6: SMMT Charger Survey: Summary of Responses to Main Points Appendix 7: SMMT Charger Survey: Full Summary of Responses Appendix 8: Electric Vehicle Charge Connector Suppliers Appendix 9: Examples of Typical Electric Vehicle Charging Points Contents 1 SMMT Report on the Current Situation and Future Direction of Introduction Electric Vehicle Charger Standards, July 2010 1. Introduction 1.1 Purpose of the study The purpose of this report is to identify the current situation, and possible future direction, regarding standardisation of the charging equipment, with specific emphasis on the charge connectors, used for conductive charging of both pure-electric vehicles and plug-in hybrid electric vehicles. 1.2 Scope The scope of this report is as follows: The report covers the components used to connect the vehicle to an electrical supply for the recharging of its battery, ie the vehicle inlet, vehicle connector, outlet socket, plug and cable. A diagram illustrating these components is shown in Appendix 2. From a standards perspective, the report predominantly focuses on the standards issued by the International Electrotechnical Commission (IEC) and by the Society of Automotive Engineers (SAE), as these have become the most influential standards in this arena. However, information on standards from other standardisation bodies has been included where relevant. From a legal requirements perspective, the report focuses on the European (EC and ECE) and US legal requirements. The report covers the legal requirements applicable to all categories of motor vehicle, ie M1, M2, M3, N1, N2 and N3. (Note: Definitions of these vehicle categories are given in Appendix 1.) The report only considers pure-electric vehicles and plug-in hybrid electric vehicles. Introduction 2 SMMT Report on the Current Situation and Future Direction of Standards and Electric Vehicle Charger Standards, July 2010 Recommended Practices 2. Standards and Recommended Practices This section gives details of the current status of the standardisation activities relating to electric vehicle charging connectors, including information on both currently published standards and those which are still under development. 2.1 SAE (Society of Automotive Engineers) The SAE Recommended Practice on electric vehicle charge connectors is SAE J1772 – Electric Vehicle and Plug-in Hybrid Vehicle Charge Coupler, which was revised and re-issued in January 2010. It contains specifications for vehicle inlet and vehicle connector to be used for the conductive AC charging of electric vehicles and plug-in hybrid electric vehicles. Specifications for a conductive DC charge coupler are still under development by the relevant SAE Task Force. The vehicle inlet and vehicle connector specification contained in SAE J1772 is designed to be compatible with two levels of conductive charging, which are defined within the Recommended Practice as: AC Level 1 – Single phase, 120V AC, 12A/ 16A, and AC Level 2 – Single phase, 208-240V AC, ≤ 80A. The charge coupler design (vehicle inlet and vehicle connector) specified by SAE J1772 is a five pin/contact design with a latching mechanism and an optional locking mechanism. The functions of the five pins/contacts are specified as follows: Contact 1 – AC Power L1. Contact 2 – AC Power L2, N. Contact 3 – Earth (ground). Contact 4 – Control pilot (allowing communication between the vehicle and the electrical energy supply equipment). Contact 5 – Proximity detection (allowing the vehicle to detect the presence of the vehicle charge connector and immobilise the vehicle). SAE J1772 also includes requirements on the data communication, EMC performance, durability, impact resistance, electrical safety and environmental performance of the vehicle charge coupler and its accessories. Note: SAE J1772 only covers vehicle inlets and the mating vehicle connectors. It does not cover electrical supply outlet sockets and mating plugs. The reasons for this are that: Charge cables for AC Level 1 charging are usually fitted with domestic plugs for use with domestic electrical outlet sockets. Standards and Recommended Practices 3 SMMT Report on the Current Situation and Future Direction of Standards and Electric Vehicle Charger Standards, July 2010 Recommended Practices For AC Level 2 charging, it is common practice in the US for the charge cable to form part of the charging station/charge point. An example of an SAE J1772 type vehicle inlet and vehicle connector is shown in Appendix 4 and a summary of the electrical ratings for this type of charge connector is shown in Appendix 5. 2.2 IEC (The International Electrotechnical Commission) The IEC standard covering the overall electric vehicle conductive charging system is IEC 61851, which covers equipment for charging electric road vehicles at standard AC voltages up to 690V and at DC voltages up to 1000V. This standard is published in separate parts under the general title “Electric Vehicle Conductive Charging System”. The main parts of this standard are: Part 1: General requirements. Part 21: Electric vehicle requirements for conductive connection to an AC/DC supply. Part 22: AC electric vehicle charging station. Part 23: DC electric vehicle charging station. IEC 61851 Parts 1, 21 and 22 have been published and are available, but Part 23 is still under development. IEC 61851 Part 1 includes definitions of the “modes” of charging and charge connection “cases”. These definitions are reproduced in Appendix 3 for information and reference. The specific requirements on the plugs, outlet sockets, vehicle connectors and vehicle inlets for the conductive charging of electric vehicles referred to in IEC 61851 are contained in a separate IEC standard; IEC 62196. This standard is published in separate parts under the general title “Plugs, Socket Outlets, Vehicle Couplers and Vehicle Inlets - Conductive Charging of Electric Vehicles”. The main parts of this standard are: Part 1: General requirements. Part 2: Dimensional interchangeability requirements for AC pin and contact tube accessories. Part 3: Dimensional interchangeability requirements for DC pin and contact tube accessories. The First Edition of IEC 62196 Part 1 has been published and is available. A Second Edition version is currently at the Committee Draft Voting stage and is expected to be published in February 2011. IEC 62196 Part 2 is also at the Committee Draft Voting stage and is expected to be published in February 2011. IEC 62196 Part 3 is still under development. The scope of IEC 62196 Part 1 covers plugs, outlet sockets, vehicle connectors, vehicle inlets and cable assemblies for conductive charging systems with a rated operating not exceeding either 690V AC, at a rated current not exceeding 250A, or 1500V DC, at a rated current not exceeding 400A. It contains requirements on the construction, electrical performance, electrical safety, EMC Standards and Recommended Practices 4 SMMT Report on the Current Situation and Future Direction of Standards and Electric Vehicle Charger Standards, July 2010 Recommended Practices performance, durability, impact resistance and environmental performance of charger plugs, outlets, connectors, inlets and cable assemblies. Note: IEC 62196 covers vehicle inlets and mating vehicle connectors, but also covers electrical supply outlet sockets and mating plugs. This is necessary because, in Europe, charging stations/charge points with permanently attached cables and vehicle connectors (Case C) are not common. Usually, the charging station/charge point only provides an electrical supply outlet socket, suitable for Case A or Case B charging connection. IEC 62196 Part 2 contains specifications, including dimensional requirements, for three types of connector interface: Type 1, Type 2 and Type 3. The Type 1 interface, which is equivalent to SAE J1772 and is for use in vehicle inlets and vehicle connectors, is a five pin/contact
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