SAE MediumHeavy Duty Task Force Update SAE Hybrid

SAE Medium/Heavy Duty Task Force Update SAE Hybrid – EV Committee Rodney Mc. Gee Chairman SAE M/H Duty TF Tuesday, September 26 th 2017 SAE TEVHYB 13 1

HD/MD TF News and Updates • J 3068 Meetings and documents – Final draft done in August – Submitted for 28 -day ballot ending on Sept-20 • Received several comments (minor) • Ballot failed due to abstention (too many waives) – Re-submit document for another ballot • Handle comments in the document’s TF • Try to get more Hybrid committee members familiar with the document before next vote • J 3105 – Regular meetings currently being held – Document currently being drafted SAE J 3068 2

J 3105 Overhead Charging Document • Overview – Document wants to standardize the interface between the Overhead infrastructure and the bus – Strategy- combine present requirements/systems with future needs and produce a standard looking forward Power Levels Power Configurations Connection Points Communications Safety Alignment Protocol

Current Situation for Three Phase Charging – There a variety of heavy and medium duty electric vehicles with on-board three phase AC chargers using a variety of plugs including some proprietary systems. – Some common issues • Some use standard NEMA or IEC outlets that are always energized for EV • Some lack plug proximity or interlock to prevent decoupling while charging, which causes arcing • Supply without ground fault protection Three-phase school bus SAE J 3068 4

Current Situation for Three Phase Charging – UL listed three-phase EVSE – Proprietary plug from Meltric – 208 VAC 80 A 3 -phase -> 30 k. W Smith EV with three-phase Clipper. Creek CS-100 -3 P three-phase 30 k. W SAE J 3068 5

J 3068 Overview • • • EVSE – Must be evaluated to UL-2594, UL-2231 Cordset / Coupler – Must be evaluated to UL-2251 – Directly refers to IEC mechanical drawings • AC --- 62196 -2 Sheets 2 -IIf and 2 -IIe • AC+DC --- 62196 -3 Sheet 3 -IVc and 3 -IVc Power levels and voltage – Voltages • USA 208/120 Y & 480/277 Y VAC • Canada 208/120 Y & 600/347 Y VAC – Power example • 16 A 480 VAC 3ø = 11 k. W • 80 A 480 VAC 3ø = 65 k. W • 160 A 480 VAC 3ø = 133 k. W SAE J 3068 6

SAE J 3068 AC single-phase 120/277/347 Y VAC AC three-phase 208/480/600 Y VAC Up to 1000 VDC (higher current) SAE J 3068 7

LIN over Control Pilot – Digital replacement for the PWM part of the control pilot – Electrically compatible with PLC – Keeping the same voltage levels (12 V, 9 V, 6 V) • Verification of Equipment Grounding Continuity • Verification of Vehicle Connection – Allows communication of basic supply parameters • Beyond the PWM 6 A-80 A supply limit • Supply voltage (208, 277, 240, 347, 480, 600) {L 1, L 2, L 3, N} • Supply current (0 -250 A) – Based on IEC-61851 -1 Edition 3 Annex D – Extra hardware required: • Some passives • Extremely low-cost transceiver ~$1 – PWM can be used where it doesn’t exceed 250 VAC between line and ground/neutral SAE J 3068 8

J 3068 at NREL • • Testing at NREL for J 3068 Energy Systems Integration Facility (ESIF) at the U. S. Department of Energy’s National Renewable Energy Laboratory in Golden, CO Transpower school bus Type-2 three-phase AC inlet Integrated motor inverter/charger (EPC Power) Bus can charges discharge into grid up to 70 k. W Test with AC EVSE shown on right (shown case-less during EMI testing) SAE J 3068 9

APTA load-out for handheld manual Specified Default ü ü ü X Three-phase AC (using 6 mm pins) Single-phase AC (including 277 VAC for example) DC charging using SAE 2847/2 Could limit usage of passenger car infrastructure SAE J 3068 Combo Inlet Optional Alternative ü ü ü X Single-phase AC (using 3. 6 mm pins) Offers direct reuse of passenger car EVSE DC charging using SAE 2847/2 Limited AC power; No three-phase; No mandatory AC lock SAE J 1772 Combo Inlet SAE J 3068 10

Example – EPC Power Integrated 3 -phase system – Single device for driving and charging modes • Single-mode – Charge Mode: 70 k. W – Drive Mode: 250 k. W • Dual-mode – Charge Mode: 140 k. W – Drive Mode: 500 k. W – Water cooled Front of class 8 truck SAE J 3068 11

Example – EDN Group On-board Charger – – – Model CMP 460 -01 16 k. W 480 (400 -550) VAC three-phase supply 350 -1022 VDC battery back Ideal for 20 A continuous / 25 A breaker Water cooled SAE J 3068 12

Example – Tesla charger topology Grid 3 -phase WYE L 1 N Each “box” is ~3. 6 k. W is a phase board Three phase boards form a 10/11 k. W module Up to 2 modules installed in vehicle give 20/22 k. W 85 -318* VAC full operating range Grid single-phase L 2 L 3 L 1 L 2/N Same on-board chargers with different hook up in inlet wiring box Three-phase on-board configuration 11/22 k. W (Also used in supercharger stack-up) * 277 VAC used in supercharger installs with 480/277 Y; Vehicles are currently configured for 85 -265 VAC limits Single-phase on-board configuration 10/20 k. W SAE J 3068 13

J 3068 News and Updates SAE J 3068 14

The End Questions? SAE J 3068 15

Single-wire LIN/CAN Bus? • • • SAE J 2411(CAN variant) and LIN bus are single ended unshielded systems and good fits for use on the control pilot J 2411 is used by Telsa for superchargers; but isn’t ideal to implement ground verification required by UL-2594 (not 12/9/6 V state compatible) LIN-CP as currently described in J 3068 and does not push single-wire baseband technology past established typical operation SAE J 2411 33. 3+ kbit/s LIN Bus 2. 2 20 kbit/s Typical Control Pilot Environment Max Capacitance 13700 p. F 10000 p. F 5500 p. F Max Nodes ~32 ~64 2 Max Length 60 m 40 m Typically < ~7. 5 m Could be longer Net Resistance 270 -4596 ohms ~1000 ohms 733/469 ohms

J 3068 – Inlet and Connector Illustration of Vehicle Inlet For mechanical specs see IEC 62196 -3 Sheet 3 -IVa For illustration purpose only (not drawn to scale) – licenses are Public Domain (source Michelle Pettinella) Illustration of Vehicle Connector For mechanical specs see IEC 62196 -3 Sheet 3 -IVc SAE J 3068 17