Charging Infrastructure

Foreword

The Auto-Cove 2.0 consortium is developing innovative study modules and training courses focused on alternative fuel vehicle service and sales across three European Qualifications Framework (EQF) levels. All courses developed within the project are funded by the European Union and are completely free for users. Upon completion, they will be published and stored in the Electude e-learning platform.

Course description

This course covers the basic principles of EV charging technology, the components of charging infrastructure, both private and public charging solutions, green charging and smart charging. By the end of the course, learners can gain both theoretical knowledge and an understanding of the practical workings across a wide range of topics, from the fundamental principles of EV charging technology and infrastructure components to electrical installation, safety, communication protocols, and management systems.

Module: Charging Infrastructure 

EV Charging Infrastructure Classification: Classification EV charging infrastructure based on factors like charging speed (Slow, Medium, Fast), connector type (AC charging: Type 1, Type 2, CCS; DC charging: CHAdeMO, CCS, Tesla Superchargers), power flow (Plug-in, Wireless, Swap), process (Bi-directional, Uni-directional), and use (Public, Private, Semi-public).

Charging Methods (Modes): Different charging modes are described, including Mode 1 (not suitable for EVs), Mode 2 (with in-cable control box, uses AC), Mode 3 (uses AC, often for public or home charging), and Mode 4 (uses DC, typically for fast charging).

Charger Types: The main types are AC Chargers and DC Chargers. AC chargers use the vehicle’s on-board charger to convert AC to DC, while DC chargers perform this conversion externally using a rectifier unit. DC chargers are also known as Off-board Chargers.

Connectors: Several connector types are detailed, including Type 1 (SAE J1772), Type 2 (Mennekes), CCS (Combined Charging System), and CHAdeMO. Type 2 is the standard in the EU for normal AC charging. CCS combines AC (often Type 1 or Type 2 based) and DC charging capabilities in a single inlet. CHAdeMO is a Japanese standard primarily for DC fast charging.

Charging Cables: The module discuss cable specifications, such as the relationship between wire cross-sectional area and the maximum current it can safely carry. A resistor installed inside the connector, positioned between the proximity pilot (PP) and earth (PE), signals the cable diameter and maximum current to the vehicle.

Communication: Communication between the charging station and the electric vehicle is crucial. The Control Pilot (CP) pin is responsible for managing the charging process and exchanging information like the maximum allowable charging current. Protocols like CAN bus are used for communication with the vehicle’s systems. Charging stations also communicate for session management.

Safety Features: Charging stations include essential safety features such as protection against short circuit, ground fault (including DC leakage detection), and overcurrent. Residual Current Devices (RCDs) are important components for safety.

Electrical Installation Components: The installation requires specific components like wires and cables, terminal blocks, circuit breakers (MCB), and Residual Current Devices (RCD/RCCB). Local regulations must be followed for installations. Adequate electrical power is a critical consideration for installation.

Charger Specifications: Detailed specifications cover input and output voltage/current/power, communication protocols (like PWM/Control Pilot for AC, PLC/CAN, OCPP for network communication), authorization methods (RFID, mobile app, Plug and Play), environmental ratings (IP and IK codes), and compliance with standards (IEC, EN, CE).

Module: Public Charging – Authentication procedure

Charging Station Authentication: This process verifies the identity of a user, device, or entity to ensure they are authorized to access EV charging services, preventing unauthorized usage and enabling billing for paid services. Common methods include using RFID Cards, Mobile Apps & QR Codes, Plug & Charge (ISO 15118) which allows automatic authentication upon plugging in, Credit/Debit Card Payment Terminals, and OCPP-Based Remote Authentication which leverages a central system for verification.

Charging Management System (CMS): This is a cloud-based platform that allows a Charge Point Operator (CPO) to monitor, operate, and manage multiple charging stations from a single dashboard. Key features and functions include remote monitoring and control, session management and automated billing, data analytics and reporting, and load balancing.

Communication Protocols: Standards are essential for communication between charging stations, backend systems, and the grid. Open Charge Point Protocol (OCPP) is a global open protocol for communication between charging stations and CPO backend systems, ensuring interoperability. ISO 15118 is an international standard defining the communication interface for Plug & Charge and Vehicle-to-Grid (V2G) capabilities. Other protocols mentioned include OSCP for smart charging based on grid availability and OCPI for connections between CPOs and service providers, aiding roaming.

Module: Private Charging Infrastructure 

Definition and Types of Private Charging: Private charging refers to charging an electric vehicle (EV) at a personal or restricted-access location. This includes Home Charging (using a wallbox or standard outlet), Workplace Charging (at a company facility), and Fleet Charging (for a company’s EV fleet). Commercial and apartment charging are also considered private charging infrastructure types.

Electrical Installation Requirements: When charging at home using AC charging (Mode 2 or Mode 3), critical considerations include ensuring the electrical circuit capacity can handle the charger’s maximum current draw (e.g., 10-16 amps for Mode 2, 16-32+ amps for Mode 3). A dedicated circuit should be used to prevent overloading other household circuits. Circuit breakers rated for the charger’s maximum current are needed for overload protection, and a Type B Residual Current Device (RCD) or equivalent is crucial to detect AC and DC leakage currents. Proper earthing/grounding is important to prevent electrical shocks.

Household Electrical System Capacity: The available power in a household depends on factors like the main electrical panel capacity (determined by the main circuit breaker rating, e.g., 25A, 40A), household wiring and circuit design (older homes may have lower capacity wiring), the utility grid connection, existing household consumption, and the type of electrical phase (single-phase typically supports 3-9 kW, three-phase supports 11-22 kW or more). Using 3-phase electricity is considered the ideal way to charge at home for higher power. Power can be calculated using the formula: Power (kW) = Voltage (V) × Current (A).

AC Charging Modes: In the European region, AC charging uses the vehicle’s onboard charger and includes Mode 2 and Mode 3 methods. Mode 2 is defined as AC Portable – Home Charger, using an in-cable protection device (IC-CPD) and typically a household outlet. Mode 3 is used for Public AC Chargers.

Mode 2 Portable Charger Characteristics and Installation: A portable AC charger is defined by a cable with an integrated control and protection unit (IC-CPD) as per IEC 61851 standard. It uses a household power outlet (standard single-phase 230V AC, typically 16A, resulting in ~3.7kW power output) or industrial sockets for higher power. Basic communication and safety features are provided by the in-cable device. It offers flexible use in various home charging scenarios. Basic requirements for installation include a suitable, properly grounded outlet, a dedicated electrical circuit with sufficient capacity (e.g., 16A or higher wiring, 20A circuit breaker for a 16A charger), and RCD protection. It is generally recommended to avoid using extension cords unless they are high-quality and support the required capacity.

Load Balancing: This is the process of optimally distributing electrical power across multiple charging stations or devices to prevent overloading and optimize energy use. Load balancing allows more EVs to charge simultaneously without exceeding the available power supply and helps prevent circuit overloads and power outages. The two main types are Static Load Balancing (fixed power allocation per charger, simple but inefficient) and Dynamic Load Balancing (smart power distribution based on real-time demand, more efficient, prevents overload, ideal for multiple chargers).

Module: Green Charging

Green Charging refers to charging electric vehicles (EVs) or other battery-powered devices using electricity from renewable energy sources like solar, wind, hydro, or biomass. Its primary purpose is to reduce the carbon footprint associated with energy consumption and promote sustainable mobility. It offers environmental benefits such as reducing carbon emissions, economic advantages like cutting electricity costs, and contributes to technological innovation in areas like smart grids and V2G (Vehicle-to-Grid) technology.

Renewable Energy Sources are natural sources that replenish over time and are a cleaner, more sustainable alternative to fossil fuels. Examples include Solar Energy, Wind Energy, Hydropower, Biomass Energy, Geothermal Energy, and Tidal and Wave Energy. Using renewable energy helps reduce greenhouse gas emissions, decrease dependence on fossil fuels, enhance energy security, and promote sustainability for future generations.

A Carbon Footprint is the total amount of greenhouse gases released into the atmosphere due to human activities. Electric vehicles help reduce carbon footprints primarily because they don’t burn fossil fuels directly, resulting in no tailpipe emissions, and they convert more energy into movement, reducing waste.

Module: Smart Charging

Smart Charging uses technology, data, and automation to optimize when, how, and where an EV charges. Its main purpose is balancing energy demand, reducing electricity costs, integrating renewable energy, and supporting grid stability. Features include Dynamic Load Balancing, Time-Based & Cost-Optimized Charging, integration with Renewable Energy, Vehicle-to-Grid (V2G) capabilities, and Remote Monitoring & Control. Smart Charging is also applied in Solar Systems for optimized charging of batteries, EVs, and appliances using available solar power.

Methods of teaching and learning description

Our approach to the design of learning and teaching involves a structured approach that is reflected in different levels of difficulty. Each course is divided into several sub-courses that aim to provide a holistic learning experience:

• Theory: This teaches the fundamental concepts and principles that are critical to understanding the subject.
• Quizzes: Interactive exercises and tests designed to test and deepen understanding of the theory.
• Labs: Practical exercises and experiments that allow learners to apply theoretical knowledge in real or simulated scenarios.
• Workshop: Interactive sessions where learners can actively participate in discussions, problem-solve and develop creative ideas.
• Test: Formal assessments to evaluate learners’ knowledge progress and competences.
• Teacher Resources: Additional materials and support for teachers to effectively organise lessons and support individual learner needs.

This structured approach aims to make learning and teaching interactive, diverse and effective by catering for different learning styles and needs and promoting comprehensive understanding and practical skills.

Innovative Study Modules and Training courses

The Auto-Cove 2.0 consortium is developing innovative study modules and training courses focused on alternative fuel vehicle service and sales across three European Qualifications Framework (EQF) levels:​

• EQF Level 4: Study modules tailored for technical and business students.​

• EQF Level 5: Training courses designed for vehicle engineering students at the tertiary level.​

• EQF Levels 4, 5, and 6: Training courses aimed at vehicle field teachers in vocational colleges and universities of applied sciences. These courses will also serve to upskill current workshop leaders, car mechanics, and professionals in vehicle sales and spare parts across all seven partner countries.

These educational initiatives aim to address the urgent need for expertise in servicing electrified and hydrogen vehicles, ensuring that both new graduates and existing professionals are equipped to navigate the evolving landscape of the automotive industry.

All courses developed within the project are funded by the European Union and are completely free for users. Upon completion, they will be published and stored in the Electude e-learning platform.

Within the AutoCoVE 2.0 framework, Electude plays a pivotal role by providing its state-of-the-art e-learning platform to all partner VET institutions. The platform offers access to nearly 2,000 technical modules, facilitating the development of innovative study materials and training courses focused on modern vehicle technologies, including electric and hydrogen-powered systems.