PHEV-EV Charger Technology Assessment with an Emphasis on V2G Operation

More battery powered electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs) will be introduced to the market in 2011 and beyond. Since these vehicles have large batteries that need to be charged from an external power source or directly from the grid, their batteries, charging circuits, charging stations/infrastructures, and grid interconnection issues are garnering more attention. This report summarizes information regarding the batteries used in PHEVs, different types of chargers, charging standards and circuits, and compares different topologies. Furthermore, it includes a list of vehicles that are going to be in the market soon with information on their charging and energy storage equipment. A summary of different standards governing charging circuits and charging stations concludes the report. There are several battery types that are available for PHEVs; however, the most popular ones have nickel metal hydride (NiMH) and lithium-ion (Li-ion) chemistries. The former one is being used in current hybrid electric vehicles (HEVs), but the latter will be used in most of the PHEVs and EVs due to higher energy densities and higher efficiencies. The chargers can be classified based on the circuit topologies (dedicated or integrated), location of the charger (either on or off the vehicle), connection (conductive, inductive/wireless, and mechanical), electrical waveform (direct current (dc) or alternating current (ac)), and the direction of power flow (unidirectional or bidirectional). The first PHEVs typically will have dedicated, on-board, unidirectional chargers that will have conductive connections to the charging stations or wall outlets and will be charged using either dc or ac. In the near future, bidirectional chargers might also be used in these vehicles once the benefits of practical vehicle to grid applications are realized. The terms charger and charging station cause terminology confusion. To prevent misunderstandings, a more descriptive term of electric vehicle supply equipment (EVSE) is used instead of charging station. The charger is the power conversion equipment that connects the battery to the grid or another power source, while EVSE refers to external equipment between the grid or other power source and the vehicle. EVSE might include conductors, connectors, attachment plugs, microprocessors, energy measurement devices, transformers, etc. Presently, there are more than 40 companies that are producing EVSEs. There are several standards and codes regarding conductive and inductive chargers and EVSEs from the Society of Automotive Engineers (SAE), the Underwriter Laboratories (UL), the International Electrotechnical Commission (IEC), and the National Electric Code (NEC). The two main standards from SAE describe the requirements for conductive and inductive coupled chargers and the charging levels. For inductive coupled charging, three levels are specified: Level 1 (120 V and 12 A, single-phase), Level 2 (208 V-240 V and 32 A, single-phase), and Level 3 (208-600 V and 400 A, three-phase) . The standard for the conductive-coupled charger also has similar charging ratings for Levels 1 and 2, but it allows higher current ratings for Level 2 charging up to 80 A. Level 3 charging for this standard is still under development and considers dc charging instead of three-phase ac. More details in these areas and related references can be found in this Oak Ridge National Laboratory (ORNL) report on PHEV-EV charger technology assessment.