EVCC - EV Charge Controller

The EVCC is controlling the whole charging behavior of the EV and manages the communication via CCS for high and low level on control pilot (CP) and plug present (PP). This is combined with inputs/outputs from user interaction and the current battery status.

component	component dialog	parameters
		property tabs General CP filter AC HIL Com HLC Timeout

Block Diagram

The EVCC is structured into several sub systems. In CP status the incoming low level PWM control pilot (CP) - according to IEC 61851-2 - defined by peak and duty cycle is translated to the states. In case high level communication is activated the communication according to ISO 15118 is handled. In the case of low-level communication, the maximum allowable current is also determined.

Control Pilot Status:

• CP_STATE_ERROR = -1
• CP_STATE_A = 0
• CP_STATE_B = 1
• CP_STATE_C = 2

Duty Cycle Status:

• DC_STATE_ERROR = -1
• DC_STATE_DC = 1 # set current via duty cycle
• DC_STATE_HLC = 2 # use higher level communication

In PP status, the plug present signal is analyzed. By evaluating the PP resistor, the maximum current capacity of the cable is determined; and if the connection is established.

Plug Present Status:

• PP_STATE_ERROR = -1
• PP_STATE_DISCONNECTED = 0
• PP_STATE_CONNECTED = 1
• PP_STATE_DEPRESSED = 2

Via input state, it is checked if CCS contactor is locked and the pins are within the allowed temperature. The Scada Input CCS auto lock controls automatic locking once the contactor is plugged. Signals are returned via output switch for locking of CCS.

Once all preconditions are full filled in enable charging the charging process can be started either by the user or automatically with activated Scada Input CCS auto lock. The defined charging current from the user is checked if it fulfills all limits and is further limited with ramps and delay dependent on start, change or stop. The final set point is sent to Power Unit.

If high level communication is mandatory the communication is further managed by ISO 15118.

input and output

The EVCC needs a lot of interaction with other model components:

• UI-in and UI_out represents the interaction with user interface. Details are described in EVCC UI.
• PU-in and PU_out represents the interaction with the Power Unit. Details can be found in the components documentation.

Interaction with the CCS-module:

input

• input CP contains all control pilot signals:

Number	Input	Description	range	default
1	CP peak	Peak voltage of PWM signal	0 - 12 V
2	CP duty cycle	duty cycle of PWM signal	0 - 1 %/100
3	CP frequency	frequency of PWM signal	0 - 10000 Hz	1000

• input PP contains all Plug present signals:

Number	Input	Description	range	default
1	PP resistor	Resistor measurement between PE and PP	0 - inf Ohm

• input state contains all states of the CCS plug:
  • Temperature sensor feedback
    • 1: too low (R < 790)
    • 2: ok (790 < R < 1280)
    • 3: switch off (1280 < R < 1420)
    • 4: too high (R > 1420)
    • 5: not defined
  • locking state
    • 0: disabled
    • 1: unlocked
    • 2: locked

Number	Input	Description	range	default
1	T AC ok	Temperature AC Pins of CCS connector are ok	1, 2, 3, 4 or 5	2
2	T DC ok	Temperature DC Pins of CCS connector are ok	1, 2, 3, 4 or 5	2
3	CCS lock state	Feedback of CCS locking actor	0, 1 or 2	0

output

• output switch for controlling the motor of the CCS inlet

Number	Output	Description	range	default
1	motor direction	direction of motor: lock (0), unlock (1)	0 or 1	0
2	motor on/off	switching motor on (1) or off (0)	0 or 1	0

SCADA

There is a SCADA element showing most important things via EVCC UI.

Component dialogue box and parameters

The EVCC subsystem is organized in four tabs defining control of the EV.

Tab 1 - General

[]

Parameter	Code Name	Description
faster execution rate	Tn	The Faster execution rate at which control of CP-signal of the inner signal processing of the component will be executed. Should be approximately 5 to 10 times faster than the Slower execution rate. [s]
slower execution rate	Tslow	The Slower execution rate, at which part of the inner signal processing of the communication components will be executed. This execution rate is identical by the connected UI subsystem. Should be approximately 5 to 10 times slower than the Faster execution rate. [s]
delay auto locking	Tlock	time delay between detection of first contact of PP until sending a locking signal to the CCS-inlet [s]
Consumption	Wh_per_kWh	Mean consumption of the EV is used in user interface to calculate charging speed. [Wh/km]
Battery Capacity	bat_cap	Nominal capacity of the battery [Ah]
nominal battery voltage	bat_volt	Nominal Voltage of the battery [V]
maximal current	bat_current_max	maximum current of the battery [A]
charge complete soc	soc_full	state of charge, when the battery is considered fully charged [%]
bulk soc	soc_bulk	state of charge , when the battery shall operate in bulk charge mode. Must be smaller than charge complete soc [%]

Tab 2 - CP filter

The tab CP filter defines the possibility of enabling a software filter for CP measurement, which should be considered for P-HIL applications with a lot of noise.

Parameter	Code Name	Description
steps	steps	simulation steps that should be considered for the filtering
delta	delta	a delta which should be neglected after filtering
Threshold DC Com Status	TH_DC_Status_s	Threshold time for duty cycle filter [s]
Threshold DC Com Imax	TH_DCC_Imax_s	Threshold for calculating maximum current [s]
Threshold ERROR	TH_ERROR	Threshold before showing an error in the CP evaluation [s]
enable CP spike filter	ena_spike_filter	if activated the filter for CP is activated

Tab 3 - AC

The tab AC defines the on board charger and its time behavior with ramps, etc..

Parameter	Code Name	Description
AC charging	AC	Checkbox activating AC charging via OBC.
maximal current	Sn_acImax_ac	maximum current of the OBC [VA]
delay start	Tstart	delay time at beginning of charging until first set point is settled [s]
delay change	Tchange	delay time at change of power until the change starts [s]
change rate start	roc_start	maximum rate of change to settle the first reference in case of start charging [1/s]
change rate stop	roc_stop	minimum rate of change to control to 0 power in case of stop charging [1/s]
change rate up	roc_up	maximum rate of change to settle a higher reference value during the charging process [1/s]
change rate down	roc_down	minimum rate of change to settle a lower reference value during th charging process in case of start charging [1/s]

Tab 4 - HL Com

Parameter	Code Name	Description
HLC type	HLC_type	Drop down box defining which type of higher level communication should be used. Currently supported 'no HLC' and 'ISO 15118-2'
Voltage Accuracy	voltage_accuracy	voltage accuracy of DC voltage in case of ISO 15118 communication [V]
Pre Charging Current	pre_charge_current	Current in case of pre charging just in the initialization of the charging process
max current limit	Imax	maximum DC fast charging current [A]
max voltage limit	Vmax	maximum DC fast charging voltage [V]
max power limit	Pmax	maximum DC fast charging power [W]
Log Level	log_level	Defines the log level for ISO 15118 communication
Log Output	log_output	Defines the log output for ISO 15118 communication

Tab 5 - HLC Timeout

Parameter	Code Name	Description
sdp response timeout	sdp_response_timeout	[ms]
supported app protocol	supported_app_protocol	[ms]
session setup	session_setup	[ms]
service discovery	service_discovery	[ms]
service detail	service_detail	[ms]
payment service selection	payment_service_selection	[ms]
payment details	payment_details	[ms]
authorization	authorization	[ms]
charge parameter discovery	charge_parameter_discovery	[ms]
charging status	charging_status	[ms]
metering receipt	metering_receipt	[ms]
power delivery	power_delivery	[ms]
cable check	cable_check	[ms]
pre charge	pre_charge	[ms]
current demand	current_demand	[ms]
welding detection	welding_detection	[ms]
session stop	session_stop	[ms]
certificate instalation	certificate_instalation	[ms]
certificate update	certificate_update	[ms]