P Van Den Bossche2

Defining and Developing Standards Peter Van den Bossche Secretary of IEC TC69 Erasmus University College Brussels Vrije Universiteit Brussel

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EV Standardization ❖ The electrically propelled vehicle ❖ Is it a Vehicle? ❖ Is it an Electrical Device?

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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

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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

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Division of labour ISO TC22 SC21 Aspects related to the electric vehicle as a whole

IEC TC69 Aspects related to electrical components and electric supply infrastructure

❖ ISO/IEC steering committee ❖ Outstanding issues

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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

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The battle of the modes ❖ Mode 1 charging: non-dedicated outlet ❖ Mode 2 charging: non-dedicated outlet with incable protection device ❖ Mode 3 charging: dedicated outlet ❖ Mode 4 charging: d.c. connection

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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

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Dangerous condition without earthing

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Mode 2 charge ❖ Use of standard socket-outlets ❖ In-cable or in-plug protection box with pilot function ❖ Transitory solution in USA

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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

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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

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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

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Hard-wired pilot conductor (example)

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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

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Mode 3 fast charge ❖ Charging via traction inverter

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Mode 3 fast charge ❖ No heavy off-board charger needed ❖ Opportunities for bidirectional working ❖ Peak-shaving ❖ Grid management

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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

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Accessories ❖ Wall side: plug and socket-outlet ❖ socket-outlet ❖ plug

❖ Vehicle side: vehicle coupler ❖ vehicle connector ❖ vehicle inlet

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Parts of the conductive connection

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Case A: cable fixed to the vehicle

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Case B: separate cable

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Case C: cable fixed to charging post

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Plugs and sockets ❖ Mode 1: use of standard plugs and sockets ❖ Compatibility with Mode 3 can be obtained ❖ Standard plugs: ❖ domestic types ❖ industrial types

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Domestic Accessories ❖ Domestic accessories are not suited for EV duties ❖ Long-term full load current ❖ Disconnection under load ❖ Mechanical stress ❖ Environmental stress

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Industrial plug standards ❖ IEC 60309 ❖ IEC 60309-1: general requirements ❖ IEC 60309-2: dimensional requirements

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IEC 60309-2 plugs ❖ International standard product ❖ Reliable ❖ Cheap ❖ Well suitable for EV use in Mode 1 ❖ Also for Mode 3 (without physical pilot)

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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 P. Van den Bossche

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Framatome plug ❖ Used by EDF in France ❖ Predates SC23H work ❖ Extra pin voor pilot ❖ Compatible in Mode 1 with standard French/Belgian socket ❖ Expensive ❖ Poor reliability P. Van den Bossche

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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 P. Van den Bossche

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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 P. Van den Bossche

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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

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The electric vehicle -61851 raising the standards Definitons of IEC Position

Universal

Basic



High power a.c./a.c. UA

High power d.c./a.c. UD

Domestic a.c. U

a.c.

 V  A

 V  A

-

-



 V  A

 V  A

-

-

       

 V  A  V  A  V  A  V  A  V  A Rated for fault  V  A  V  A

 V  A  V  A  V  A  V  A Rated for fault  V  A  V  A

 V  A  V  A  V  A  V  A Rated for fault  V  A  V  A

 V  A  V  A  V  A  V  A Rated for fault  V  A -



 V  A

 V  A

 V  A

-

  

 V  A -

 V  A -

 V  A -

 V  A  V  A

Functions

B High power d.c./a.c. High power d.c./a.c High power a.c. L L L Neutral PE Control pilot Communication  (+) Communication  (-) Clean data earth Power indicator Power indicator

Table .: Overview of the vehicle interface requirements P. Van den Bossche

The design of the interface did grow with the other specifications in the developing

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Vehicle connector ❖ 1990s designs: ❖ AVCON (US) ❖ Maréchal (F)

❖ Common vehicle inlet for normal or fast charging ❖ Connectors in light and heavy version

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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

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New proposal for vehicle connector ❖ Single phase power ❖ Earth ❖ 2 signal contacts

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Battery connectors ❖ Used for industrial vehicles ❖ Used as internal connector ❖ Not for operation under load ❖ Not suitable for consumers

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The first ever EV standard (1913)

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The first international EV standard ❖ British Standard BS74

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Regional standardization ❖ Europe ❖ Activities in CENELEC TC69X transferred to IEC level

❖ USA ❖ SAE standardization

❖ Japan ❖ JARI standardization

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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

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