Introduction to the Principles of Electric Vehicle Charging System

With the increasing use of pure electric vehicles and the increasing demand for charging, the market has put forward higher requirements for the safety and convenience of vehicle charging. Convenient, safe, and fast charging is the consistent demand of the market for vehicles.

There are two main charging systems for pure electric vehicles, one is AC charging, which is slow charging, and the other is DC charging, which is fast charging. The composition, electrical principles, and control methods of the two charging methods are different.

AC charging system

Composition of AC charging

AC charging means that the voltage input from the power grid to the vehicle is AC, which can be 220V AC one-way or 380V AC Three-phase electric power. AC power enters the vehicle charger through standard charging plugs and sockets, which then converts AC power into DC power to charge the power battery and complete basic AC charging.

AC charging components mainly include on-board charger, AC charging socket (AC charging socket harness), charging line, AC Charging station or 220V AC power supply and vehicle controller (VCU, BMS).

The AC charging socket and on-board charger are fixed on the vehicle, the charging line is delivered with the vehicle, and the AC Charging station is fixed in the parking lot. The functions of each component are as follows:

(1) The on-board charger is a key component of the AC charging system, which converts AC power into DC power according to control commands to charge the battery.

(2) AC charging socket is a national standard component that serves as the interface for connecting vehicles to the external power grid. The interface consists of 2 signal circuits, 1 grounding circuit, 1 zero line circuit, and 3 live line circuits, totaling 7 interfaces. Depending on the input voltage of 220V AC or 380V AC, the corresponding live line interface should be applied.
 

(3) The vehicle controller is responsible for monitoring the status of the vehicle and issuing control commands to the on-board charger to make it work or stop working, controlling its working current and voltage, etc. It is the control brain for vehicle charging.

(4) Mode 2 charging line is a charging line that connects the external power grid to the vehicle and directly provides 220V AC power to the on-board charger. The function box on its cable can detect the status of the vehicle and the power grid, connect or disconnect the power supply to the vehicle, and has a certain protective function. According to the standard requirements, the input charging current is limited to 13A and the input voltage is 220V AC. Therefore, when using the charging line in Mode 2 for charging, the maximum input power of the on-board charger is 2860W, which means that the charging time will be extended.
 

(5) The AC Charging station is also a part of the vehicle connecting to the external power grid, which directly supplies 220V AC or 380V AC power to the on-board charger. It also has the function of detecting the status of the vehicle and the power grid, connecting or disconnecting power to the vehicle. The power supply voltage of the Charging station is 220V AC and 380V AC, depending on the output power of the Charging station. According to the standard requirements, if the output current of the AC Charging station is greater than 32A, the power supply voltage must be 380V AC. Therefore, when the AC Charging station is used for charging, the charging power is large, that is, the charging time will be shortened.

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