Validation tests for DC charging stations. Klaus Kersting Product Manager EV/HEV

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1 Validation tests for DC charging stations Klaus Kersting Product Manager EV/HEV

2 General Company Engineering & Testing Project examples

3 Engineering and Testing Edrive Control System Development Definition & specification, software development, functional safety Emotor / hybrid powertrain and vehicle dyno testing 160kW battery simulator for Emotor dyno Testing with battery simulator and 2WD and 4WD dynos Charger testing and Charger interface development AC and DC charger testing up to 150 kw, with battery simulator Development and validation for different charging protocols according IEC61851 / SAE J1772 / ISO15118 / DIN70121 Vehicle Prototyping HMI, Charger interface, Prototyping and Integration of components, Setup of battery systems, First run, Calibration and Validation Vehicle Benchmarking Performance & Driveability, Consumption & Range, Battery performance in extreme temperatures, Charger, DCDC and Emotor efficiency, Driveline architecture & Transmission teardown, NVH, Regen brake

Development and validation for different charging protocols according IEC61851 / SAE J1772 / ISO15118 / DIN70121 Vehicle Prototyping HMI, Charger interface, Prototyping and Integration of components,

4 Project examples E-Cabstar: Light Truck Electrification Electrification of a light truck on its shortest wheelbase version with full electric powertrain and replacement of all auxiliary systems Eborn³ - Passenger car designed for taxi use Concept development of an urban vehicle exploring new architecture solutions with electric vehicles itorq: Torque Vectoring Vehicle Demonstrator Electrification of 4x4 passenger car with 4 in-board EMs as development and validation platform for torque vectoring algorithms ishare: Advanced Urban Mobility Vehicle for Car-Sharing Complete Vehicle Development Project from concept to fully functional prototype of an urban vehicle for car-sharing fleets Volar-e: High Performance Electric Vehicle EU funded project to develop a high performance EV with many innovative features such as and ultra fast charging system or an advanced range estimator

Electrification of 4x4 passenger car with 4 in-board EMs as development and validation platform for torque vectoring algorithms ishare: Advanced Urban Mobility Vehicle for Car-Sharing Complete

5 Validation tests for DC charging stations Background CHAdeMO & CCS Testing Methods Conclusions

6 Background Automotive OEMs have to take care of their brand image, therefore a safe battery operation while driving and also during charging is required. Compatibility with public chargers is taken for granted by the customer. safety standards compatibility IDIADA is certification partner of big automotive OEM for CHAdeMO DC and also for AC mode 3 charger testing to ensure vehicle compatibility CHAdeMO association founded in 2010, IDIADA is member since January 2011 Within volar-e project, IDIADA enhanced its test equipment for Combo 1 and Combo 2 charger test capability, IDIADA is an active member in a subworking group specifying conformity tests for Combo

safety standards compatibility IDIADA is certification partner of big automotive OEM for CHAdeMO DC and also for AC mode 3 charger testing to ensure vehicle

7 Charging Modes and Communication Charge Mode AC Mode 3 w/o HLC (high level communication) Communication Type Control Pilot, 1000Hz PWM, duty cycle to determine current capability, voltage level indicates state AC Mode 3 with HLC (not yet installed) DC CHAdeMO Mode 4 DC Combo Mode 4 (not yet installed) Control Pilot, 1000Hz-5% PWM with modulated Power Line Communication (PLC) signal of 30MHz separate CAN signal plus 4 digital wires Control Pilot, 1000Hz-5% PWM with modulated Power Line Communication (PLC) signal of 30MHz

Mode 4 DC Combo Mode 4 (not yet installed) Control Pilot, 1000Hz-5% PWM with modulated Power Line Communication (PLC) signal of

8 Main differences of CHAdeMO & Combo charging systems CHAdeMO system Combined Charging System Max ratings: 125A / 500V Mandatory diode in HV circuit, no precharge CAN communication, redundant discrete wires Simpler architecture Gun locking mechanism: Controlled by charger, solenoid within gun Specification definition: By CHAdeMO association, not public Certification by CHAdeMO association 200A / 850V Optional diode, voltage precharge PLC communication via pilot line Controlled by vehicle, mechanism within inlet IEC standard, public certification by approved laboratories > chargers installed worldwide (2013) First chargers available, not yet installed, > EVs on market (2013) first vehicles announced for end of 2013 no added value services within specification first V2H projects successful, no dynamic charger power adjustment Communication prepared for V2G, charge scheduling, multi-media services, plug & charge (automatic authentification for payment)

850V Optional diode, voltage precharge PLC communication via pilot line Controlled by vehicle, mechanism within inlet IEC standard, public certification by approved laboratories > 3.

layers Contract, Payment, Service Discovery, Charge Parameters Cable Check (Isolation) Precharge Current

9 Combo communication EVSE starts 5% PWM indicating High Level Communication SLAC Physical Layer Encryption, setup of TCP/IP network connection EV requests to use DIN70121 or ISO15118 Protocol Network and transport layers Contract, Payment, Service Discovery, Charge Parameters Cable Check (Isolation) Precharge Current Demand charging phase... Welding Detection Application Layer Session Stop Finalization of Data Link layer Physical Layer

10 Testing methods Vehicle Detection of vehicle specific incompatibilities: Detection of unexpected behaviour in abuse operation. Charging current waveform from on-board charger. Real ripple waveform in DC charging EV Simulator Automatic testing procedure repeatability, less manual operation Long time testing durability and temperature test Simulation of different EV characteristics (timings, CAN messages, voltage levels, capacities) Upgrade possible to new charging standards (GB/T)

Real ripple waveform in DC charging EV Simulator Automatic testing procedure repeatability, less manual operation Long

11 Test requirements workflow new test item is added in the checksheet requirement is identified from the standard new simulator test is programmed in a fast user-friendly language requirement can be tested with the EV Simulator

new simulator test is programmed in a fast user-friendly

12 EV charging simulator HW overview I/O manager HV Sensor NI Compact DAQ Resistor box Battery simulator Power relay box CAN buses DC power AC power Analog&PLC communication Analog signals Digital signals USB

13 Capabilities of EV charging simulator Full power test for DC charger based on battery simulator V2G ready! Ready for Mode 3 & 4, CHAdeMO and CCS PLC (ISO HPGP) capability for CCS Automated testing with only manual plugging Automated test report generation Adaptable to new normative requirements Normal use, misuse and abuse tests

Ready for Mode 3 & 4, CHAdeMO and CCS PLC (ISO15118 - HPGP) capability for CCS

14 Conclusions IDIADA has built up resources and know-how for charger testing and can support any activities for charger testing: Battery simulators are the most effective tool for DC fast charger testing due to their capability to simulate different vehicles and malfunctions IDIADA participates in the CHAdeMO workgroup as well as in the standardization process fot the Combined Charging System IDIADA is used to work in international projects with international teams More than 100 AC and DC charging stations already tested by IDIADA

malfunctions IDIADA participates in the CHAdeMO workgroup as well as in the standardization process fot the Combined Charging System

15 For further information: Applus IDIADA Main Technical Centre L Albornar PO Box 20 E Santa Oliva (Tarragona) Spain T F [email protected] Applus IDIADA Belgium T (Brussels) [email protected] Applus IDIADA Brazil T (Curitiba) T (São Paulo) T (Tatuí) [email protected] Applus IDIADA China T (Beijing) T (Changchun) T (Chongqing) T (Guangzhou) T +86 (21) (Shanghai) T +86 (772) (Liuzhou) [email protected] Applus IDIADA Czech Republic T (Hradec Králové) T (Liberec) T (Mladá Boleslav) [email protected] Applus IDIADA France T +33 (0) (Sèvres CEDEX) [email protected] Applus IDIADA Germany T +49 (0) (Ilsfeld) T +49 (0) (Ingolstadt) T +49 (0) (Munich) T +49 (0) (Wolfsburg) [email protected] Applus IDIADA India T (Bangalore) T (Chennai) T (New Delhi) T (Pune) [email protected] Applus IDIADA Italy T (Turin) [email protected] Applus IDIADA Japan T +81 (0) (Tokyo) [email protected] Applus IDIADA South Korea T (Seoul) [email protected] Applus IDIADA Madrid T (Madrid) [email protected] Applus IDIADA Malaysia T (Kuala Lumpur) [email protected] Applus IDIADA Poland T (Poznan) [email protected] Applus IDIADA Russia T +7 (831) (Nizhny Novgorod) [email protected] Applus IDIADA Saudi Arabia T (Riyadh) [email protected] Applus IDIADA Taiwan T (Lu-Kang) [email protected] Applus IDIADA Thailand T (Bangkok) [email protected] Applus IDIADA Turkey T (Istanbul) [email protected] Applus IDIADA UK T +44 (0) (Hinckley) [email protected] Applus IDIADA USA T (Detroit) [email protected] CTAG IDIADA T (Pontevedra) [email protected]

com Applus IDIADA Brazil T +55 41 3373 0411 (Curitiba) T +55 11 4330 9880 (São Paulo) T +55 15 3205 2952 (Tatuí) e-mail: idiada_brasil@idiada.

Standardisation needs and testing methods for multiple-outlet chargers. Klaus Kersting, Product Manager EV/HEV, Applus IDIADA July 2014

Standardisation needs and testing methods for multiple-outlet chargers Klaus Kersting, Product Manager EV/HEV, Applus IDIADA July 2014 IDIADA company introduction Automotive service provider for: Engineering