CHARGING STATIONS

 All-electric vehicles, also referred to as battery electric vehicles (BEVs), have an electric motor instead of an internal combustion engine. The vehicle uses a large traction battery pack to power the electric motor and must be plugged in to a wall outlet or charging equipment, also called electric vehicle supply equipment (EVSE). Because it runs on electricity, the vehicle emits no exhaust from a tailpipe and does not contain the typical liquid fuel components, such as a fuel pump, fuel line, or fuel tank.

Key Components of an All-Electric Car

Battery (all-electric auxiliary): In an electric drive vehicle, the auxiliary battery provides electricity to power vehicle accessories.

Charge port: The charge port allows the vehicle to connect to an external power supply in order to charge the traction battery pack.

DC/DC converter: This device converts higher-voltage DC power from the traction battery pack to the lower-voltage DC power needed to run vehicle accessories and recharge the auxiliary battery.

Electric traction motor: Using power from the traction battery pack, this motor drives the vehicle's wheels. Some vehicles use motor generators that perform both the drive and regeneration functions.

Onboard charger: Takes the incoming AC electricity supplied via the charge port and converts it to DC power for charging the traction battery. It also communicates with the charging equipment and monitors battery characteristics such as voltage, current, temperature, and state of charge while charging the pack.

Power electronics controller: This unit manages the flow of electrical energy delivered by the traction battery, controlling the speed of the electric traction motor and the torque it produces.

Thermal system (cooling): This system maintains a proper operating temperature range of the engine, electric motor, power electronics, and other components.

Traction battery pack: Stores electricity for use by the electric traction motor.

Transmission (electric): The transmission transfers mechanical power from the electric traction motor to drive the wheels.

HYBRID ELECTRIC VEHICLE

Hybrid electric vehicles are powered by an internal combustion engine and one or more electric motors, which uses energy stored in batteries . A hybrid electric vehicle cannot be plugged in to charge the battery. Instead, the battery is charged through regenerative braking and by the internal combustion engine. The extra power provided by the electric motor can potentially allow for a smaller engine. The battery can also power auxiliary loads and reduce engine idling when stopped. Together, these features result in better fuel economy without sacrificing performance.

PLUG IN HYBRID VECHICLE

Plug-in hybrid electric vehicles (PHEVs) use batteries to power an electric motor and another fuel, such as gasoline, to power an internal combustion engine (ICE). PHEV batteries can be charged using a wall outlet or charging equipment, by the ICE, or through regenerative braking. The vehicle typically runs on electric power until the battery is nearly depleted, and then the car automatically switches over to use the ICE.

Batteries for Electric Vehicles

Energy storage systems, usually batteries, are essential for all-electric vehicles, plug-in hybrid electric vehicles (PHEVs), and hybrid electric vehicles (HEVs).

Types of Energy Storage Systems

The following energy storage systems are used in all-electric vehicles, PHEVs, and HEVs.

Lithium-Ion Batteries

Lithium-ion batteries are currently used in most portable consumer electronics such as cell phones and laptops because of their high energy per unit mass relative to other electrical energy storage systems. They also have a high power-to-weight ratio, high energy efficiency, good high-temperature performance, and low self-discharge. Most components of lithium-ion batteries can be recycled, but the cost of material recovery remains a challenge for the industry. 

Lead-Acid Batteries

Lead-acid batteries can be designed to be high power and are inexpensive, safe, and reliable. However, low specific energy, poor cold-temperature performance, and short calendar and lifecycle impede their use. Advanced high-power lead-acid batteries are being developed, but these batteries are only used in commercially available electric-drive vehicles for ancillary loads.

Nickel-Metal Hydride Batteries

Nickel-metal hydride batteries, used routinely in computer and medical equipment, offer reasonable specific energy and specific power capabilities. Nickel-metal hydride batteries have a much longer life cycle than lead-acid batteries and are safe and abuse tolerant. These batteries have been widely used in HEVs. The main challenges with nickel-metal hydride batteries are their high cost, high self-discharge and heat generation at high temperatures, and the need to control hydrogen loss.

From the above table we can compare different objectives on the batteries which are mostly used in EV. We now have discussed about WHAT ARE EV AND THEIR ADVANTAGES also we have seen about DIFFERENT BATTERIES WITH THEIR COMPARISON. As battery is one the main component of the EVs but we need to setup the charging station on large scale to increase the usage of EVs in our daily life. 

What is an Electric Vehicle Charging station?

An EV charger is a piece of equipment that supplies power for electric vehicles. Its main job is to recharge the battery of an EV to keep the vehicle in motion. Most eclectic vehicles’ batteries can only be charged with direct current (DC) power, yet some EV have a charger that converts alternating current (AC) electricity into DC and then sends this power to the vehicle’s charging port.

 

What are its types?

There are various types of electric vehicle charging stations in the market, making it a little confusing for some.

Essentially, it comes down to two main considerations: WHERE you decide to charge and HOW FAST you decide to charge. These are interconnected, and the charging speed will depend on which EV you own, its battery capacity and what sort of charging system you are using.

Another key thing to know from the outset: There are three categories or types of charging: Trickle Charge, AC Charge and DC Charge. 

TRICKLE CHARGE

When your EV needs a little more power to get through the day, choose Trickle Charge. This mode delivers a gentler charge. It is perfect for charging smaller vehicle types as it has a standard three-prong, 220V plug that is used to charge your vehicle.

AC CHARGE

It is the most common charging method for EVs because it’s the easiest. The charge point gets wired straight into your home’s network, then plugs into your car through a cable, sending electricity to the car battery

DC CHARGE

Fast chargers take advantage of direct current, which goes directly from the source to the vehicle. Fast chargers bypass the converter, which enables the batteries to charge faster.

You have two options – charging your EV at home using your own domestic mains electricity supply or making use of public charging stations. This will affect the types (and speeds) of charging available to you.

Option 1:

Home charging

Around 80% of all EV charging is currently done at home. Usually overnight while owners sleep – waking to a fully charged battery the next morning that almost always provides more than enough EV range for most people’s daily travel needs.

There are TWO TYPES of home charging available: Using Trickle Charge with your household current or AC Household Charge with an installed wall box. Here are the key differences:

TRICKLE CHARGE

·        Provides charging through a standard (three-prong) 220V plug that comes with your EV. The other end is simply plugged directly into your EV.

·        Doesn’t require installation of additional charging equipment.

·        Can deliver 13 to 16 km of range per hour of charging.

·        Charging speed: approx. 65 km of range in 5 hours (overnight), or 200 km in 14 hours.

AC HOUSEHOLD CHARGING WITH WALLBOX

·        The most common and recommendable home charging option.

·        Provides charging through a 230V outlet which allows charging 3 to 4 times faster than Trickle Charge – depending on the acceptance rate of your specific model and the charger.

·        Especially useful if you have time to top up your electric vehicle overnight: it takes around 6 hours to fully charge a 40 kWh battery car.

·        Requires the installation of a dedicated EV charging wall box, which should be fitted by a trained electrician.

·        Ideal if you have a garage or driveway in which it can be positioned.

Option 2:

Public charging

 Increasingly convenient thanks to the ever-growing network, these stations can often be located throughout urban centers in particular and allow you to top up your battery on the go if you need to travel longer distances.

Public charging offers AC Charging with a wall box or – in most cases – DC Fast Charging.

And both options are quicker than charging at home: AC Public Charging can be 3 to 10 times faster than AC Household Charging, depending on the charging station output and your EV’s capacity to handle AC Chargers. All DC Charging stations are considered fast, as the following figures show:

DC FAST CHARGERS

·        Currently the quickest way to charge an electric vehicle.

·        Provides charging power above 50kW through a voltage above 450V and current up to 125A.

·        Is capable of charging from 20 to 80% of charge in approx. 40 minutes.

·        Utilizes Combo DC (CCS for Combined Charging System).

AC versus DC charging explained

·        An AC charger supplies the EV’s onboard charger, which then converts the AC power to DC allowing the battery to charge. The size of the onboard charging device is constrained by space. Due to this limited space, the amount of power they can deliver to the battery is relatively low. Which means that charging is typically slower.

·        A DC fast charger bypasses the onboard charging device, supplying power directly to the EV’s battery. The DC charger is external to the car, so it isn’t constrained in size or cost. Meaning that charging is typically much faster.

So which connector for which charging type?

You might be asking yourself if you need an adapter for different charging methods and types. At the moment, there isn’t a universal connector for all EVs and all chargers. But the different connector types do correspond with the different levels of charging, making things easier for EV drivers.

Here’s an overview of the main connector types:

What is Cost of setting up an electric car charging station in India?

The Indian government has been aggressive with promoting electric vehicles to push for a faster adoption of EVs. However, the biggest challenge that EV-manufacturers face with attracting buyers is the lack of adequate infrastructure. In fact, in its current state, the EV charging infrastructure in the country is so limited that there would be a havoc in case the number of electric vehicles rises exponentially.

Cost of EV charging station setup in India

A good DC fast charger setup could cost more than Rs 10 lakh. In case you plan to have, say, 4 of these, one would need to make a high initial investment. This is true especially if you consider the cost/rent of the land. Furthermore, the investment might vary based on the type of chargers installed. This cost could easily go up to Rs. 40 lakhs. Below, we have a rough estimate of cost of EV charging station setup in India based on a generic scenario and a supply of 250KVA EV Stations.

·        New Electricity Connection (250 KVA): 7,50,000 /-.

·        Civil Works: 2,50,000 /-.

·        EVSE Management Software + Integration: 40,000 /-.

·        Technicians, Manpower, Maintenance, etc. : 3,50,000 /- yearly.

·        Advertising and Promotion: 50,000 /-.

·        Land Lease (if the land is at lease): 6,00,000 /- yearly.

·        Total Approximate: Rs. 40,00,000 /- (First year including setup and if the land is at lease).

·        Annual maintenance from the second year: Rs. 10,00,000 /- (Including land lease).

·        Operational cost: Software maintenance, technical maintenance, Manpower.

Charger Type	CCS – 60kW	CHAdeMO – 60kW	Type 2 AC – 7/22kW	Bharat DC-001 – GB/T	Bharat AC-001
Approximate Cost (in INR)	12,50,000	12,50,000	1,00,000	2,40,000	60,000

Infrastructure Requirements for EV Charging Stations

Obviously, establishing an electric vehicle charging station will require infrastructure. First of these is, well, electricity. This can be sourced from the grid. However, one would require the necessary approvals from the same. Here is a list of requirements for setting up an EV charging station –

·        Transformer and subsequent substation.

·        33/11KV cable and supporting equipment for metering/termination.

·        Enough space for entry, parking and exit of electric vehicles.

·        Enough electric charging points to charge multiple vehicles at once.

·        Local certifications based on state requirements.

Government Initiatives

To help make EVs popular, the Government of India has even taken steps to bring down the cost of EV charging station setup. This has been done by removing the need of having a licence to build EV charging infrastructure. Furthermore, one can choose any charger type and make an investment as per his convenience. The government has even made it compulsory for electricity boards to provide new EV charging stations with a connection “within 7 days in metro cities, 15 days in other municipal areas and 30 days in rural areas.”

India Launches E-Amrit Portal on EVs at COP26

One-Stop Destination for All EV-Related Information

E-Amrit is a one-stop destination for all information on electric vehicles—busting myths around the adoption of EVs, their purchase, investment opportunities, policies, subsidies, etc.

E-Amrit intends to complement initiatives of the government on raising awareness on EVs and sensitizing consumers on the benefits of switching to electric vehicles. In the recent past, India has taken many initiatives to accelerate the decarbonization of transport and adoption of electric mobility in the country. Schemes such as FAME and PLI are especially important in creating an ecosystem for the early adoption of EVs.

References:

Plug-In Electric Vehicle Handbook- https://afdc.energy.gov/files/pdfs/51227.pdf 

Charging Infrastructure For EV - https://powermin.gov.in/sites/default/files/webform/notices/Final_Consolidated_EVCI_Guidelines_January_2022_with_ANNEXURES.pdf 

Authors :

Karansinh Gaware

Tanmay Kasliwal

Aditya Khabiya

Sushom Khaire

Amit Khare

Guide : Prof. S.D. CHOUGULE