Agile Approach for Brisk Global Expansion of EVs

Mirle Seetharamu Manjunath

Overview

Electric Vehicles (EVs) are steadily getting noticed across the world as a Next Generation Commodity. Even though Steam vehicles and EVs had a significant share in the U.S. at the beginning of 20^th Century, Internal Combustion Engine based Vehicles won the Race at that Time and became Popular with the Public.

And, in recent years, Battery-powered EVs (BEVs) have received increasing attention. Nissan’s LEAF was launched in 2010 and now it has a Global Cumulative Sales of more than 600,000 Units (as of February 2023). In addition, the Global Sales of Electric Vehicles have doubled in each of the past two Years.

Governments around the World, which are keen on achieving Long Term Targets for Climate Change mitigation & aim for reducing the Petroleum Use, have introduced Subsidies, Incentives & Key Policies to Step-Up the EV Sales. However, the pace of EV Growth in every Major Auto Market is considerably slow.

One of the Factors which can attribute to EV’s Slow Growth might be related to the availability of Electric Vehicle Charging Infrastructure (EVCI) & easier access to the same. The most Common Location for EV Charging is likely to be at Home, however, the availability of Public Charging Infrastructure has become a necessity and is required to promote further use of EVs.

This White Paper highlights about some of the Major Challenges related to Setting up of EV Charging Infrastructure & highlights on the TCS’s Agile based Phased Approach Solution, which can solve these Problems to a greater extent thereby becoming a Major Boosting Factor for Brisk Global Expansion of EVs by bridging the Gap in Terms of Technology thereby resulting in Cost Benefits.

Need for Developing Infrastructure for Rapid Charging

To realize a decarbonized society, Countries are promoting the conversion of Gasoline and Diesel vehicles to EVs. Automakers in various countries, including Japan, have set EV sales targets, and the spread of EVs may accelerate.

To promote the spread of EVs, it is essential to develop the Infrastructure.

There are two main ways to charge EVs:

- Normal Charging

- Fast Charging.

Since Normal Charging is undertaken at home and the Charging equipment can be purchased relatively cheaply, it is considered that the Charging Equipment will be considered as a Set, along with EV.

On the other hand, Quick Charging is mainly used on the go, but it is expensive and requires space, therefore, maintenance is not easy. Just as there is a Gasoline Station for Gasoline Cars, the installation of a Quick Charging facility everywhere, where an EV is used, is an important factor in the spread of the EVs.

1. Normal Charging / Slow Charging (Single-Phase AC charger)

Approximate Charging Duration: 8 ~ 10 Hours
Locations of Usage: Residential, business, accommodation, etc.

2. Quick Charging / Fast Charging (DC Charger or 3-phase AC Charger)

Approximate Charging Duration: ~ 30 Minutes
Locations of Usage: Commercial facilities, leisure, Highway Service Areas / Parking Areas, Convenience Stores, etc.

Nowadays, there are even High-Capacity BEVs that can handle Long Distance Travel. In some cases, there are additional safety standards that are common to all Countries or Unique to each country so that there is no risk of fire or explosion.

Conforming to these standards is a consideration not only during the manufacturing of batteries, but also in the introduction and deployment of EV Charging Infrastructure (EVCI). At TCS, we have extensive experience working on EVCI deployments in countries including Mexico, Barbados, Australia, New Zealand, Bhutan, South Korea, Norway, Bulgaria, Romania and the UK. Those experiences have made it clear that there are several considerations that need to be taken into account, when working on EVCI deployments.

Key Considerations and Challenges for Installing an EV Charging Infrastructure (EVCI)

1. Difficulty in understanding the Fluctuations in National / Regional Electricity supply

Understanding National and Regional Electricity Quality is important. If an EV's Onboard charger is not designed according to the power conditions of the Country or Region in which it is used, Voltage Fluctuations and Harmonics will lead to performance degradation. Discontinuous charging can also occur, resulting in Battery Degradation and reduced Charging Efficiency.

2. Differences in Laws and Standards by Country/Region

EVCIs must be installed in accordance with National and Regional Laws and Standards. As Laws and Standards vary from Country to Country and region to region, the same installation method cannot be applied to all Countries / Regions.

3. Selection of appropriate EVSE (Electric Vehicle Service Equipment) Suppliers

Depending on the state of Electric Power in one’s Country or Region, one may need to charge the EV with the appropriate EVSE, but identifying a compatible EVSE Supplier can be time-consuming and laborious. And, One should also perform rigorous Testing to ensure compatibility between EVSE and EV.

4. Choosing the right Installer for each Country / Region

Like EVSE suppliers, choosing the right Installer for installing the charger and provide maintenance support for each Country / Region, is time consuming and laborious. One should also check to see if the Installer can create an EVCI Installation Manual that lists out the proper procedures required for Installation.

5. Consultation with National / Regional Government Agencies for agreement on Charging Specifications

Consultation with government agencies is required on:

i. Basic EV Charging Specifications

ii. Administrative support needed for setting up EVCI

iii. Obtaining agreement on applicability of EVCI specifications

Overcoming challenges with an Agile based Phased Approach

Based on these considerations and issues, TCS has set three goals, and we believe that the following procedures will enable efficient Deployment of EVCI keeping safety in mind.

Fig 1 – TCS’s 3 Key Objectives

EVCI deployment proceeds in Eight Phases. Deliverables in all Phases will continue to improve through small, frequent Releases. This Phased approach allows for early creation of Deliverables and efficient EVCI Deployment.

Fig 2 – EVCI Installation Flown

Phase 1: Understanding the National / Regional Regulation and Standards

- Regulations and Standards vary by Country / Region and EV Charging Infrastructure must be set up according to local Regulations and Standards, so understanding them is essential.

- Purchasing of National / Regional Regulations and Standards documents related to EVCI, to ensure a thorough understanding of National / Regional requirements. EV manufacturers/EV charger manufacturers need to correctly understand the requirements for installing EVCI in their region.

- The following Parameters are stipulated by the Regulations and Standards of major Countries / Regions;

Power System
Wiring methods and wiring materials
Grounding (ground system)
Circuit Breaker for Overcurrent Protection
Circuit Breaker for Leakage Protection
Socket (plug and outlet)
Safety
Surge Protection Device

Phase 2: Understanding Country / Regional power quality

- With the approval of the National / Regional Administration, visiting the Identified Region / City to analyze and understand the Power quality. This will provide valuable information for redesigning EV’s In-vehicle Chargers for each Local Power supply condition. It also helps to improve local power supply conditions to ensure safe and reliable charging.

- After the EV infrastructure is deployed, this phase is undertaken again. To understand power quality fluctuations while the EV is charged, we analyze whether the following phenomena are observed:

Voltage Fluctuations exceeding prescribed limits
Frequency Harmonic fluctuations exceeding prescribed limits

Phase 3: Identification and Verification of suitable Chargers/EVSEs for Installation

- Send and collect questionnaires to Charger manufacturers to understand Charger Specifications, Features and Certification details.

- List manufacturers that meet EV manufacturer requirements

- Use EVs and conduct joint testing with EV and Charger Manufacturers

- Determine compatibility of Tested Chargers with EVs

Phase 4: Help EV Makers identify and finalize the National / Regional Installers

- Understand the capabilities of local Installers by sending and collecting questionnaires to potential Installers, focusing on:

Whether the candidate contractor has a license to undertake the installation
Experience in handling EV Infrastructure and related cases and Electrical Equipment
Have an understanding of Laws and Standards related to EV Infrastructure and a checklist thereof
Whether Post-Installation Maintenance and Service Support is available.
If necessary, visit the Site to meet with Shortlisted Installers.

Phase 5: Assist National / Regional Installers / EV Manufacturers in preparing installation Manuals

- Installation manuals are very important documents for National / Regional Installers / EV Manufacturers to install EVCI

- It is important that Equipment (Wiring, Sockets etc.) related to the EV Charging Infrastructure should be dedicated and should not be used for other purposes. When checking the Installation Manual, also confirm that each device is "Dedicated".

- To achieve the Three Key Goals of EVCI recommended by TCS, we ensure that the Installation manual includes the following elements:。

Awareness of the requirements of EV manufacturers
For Wiring diagrams, whether the following parameters are set for specific Application. Are they in compliance with National / Regional Regulations and Standards.
- Wiring methods and materials
- Grounding (ground system)
- Circuit breaker for overcurrent protection
- Circuit breaker for leakage protection
- Socket (plug and outlet)
- Safety
- Surge protection device

Whether the Checklist has been prepared to verify the validity of the Installation manual prepared by the National / Regional Installer
Whether Installation Precautions are included

- Once the Installation manual is ready, training sessions will be conducted with National / Regional Installers to help them understand the importance of the Installation.

- The Installation manual ensures that the wiring design and its components comply with National / Regional Regulations and Standards in terms of Performance, Safety, Weather resistance and Electromagnetic compatibility (EMC) requirements.

Phase 6: Assist National / Regional Installers / EV Manufacturers while installing EV Charging stations

- Once the Installation Manual is ready, the National / Regional Installers / EV Manufacturers typically install according to the Installation Manual.

- A verifier should verify the Installation to ensure that the Installation is as per the Manual.

- The verifier will be onsite to verify the installation as per the verification checklist. The verifier will then share the results of the verification with the National / Regional Installers / EV Manufacturer, as to whether it was installed correctly.

- If the verification reveals an issue / mistake, then the verifier will instruct the National / Regional Installers / EV Manufacturer to install it correctly. If it is installed again, verify again to ensure compliance with the Installation Manual.

Phase 7: Assist National / Regional Installers / EV Manufacturers with maintenance of EV Charging Stations

- Once the Installation is complete, problems may arise due to EVSE issues or fluctuating power quality that may lead to EV Charging Problems.

- Remote maintenance, which can monitor problems, is a good way to address such problems. Implement remote maintenance using a commercial product, such as an ELSPEC Power Quality Analyzer.

Phase 8: Help EV manufacturers improve EVCI capabilities

- When EVCI is introduced, some EV manufacturers will try to implement a Vehicle to Grid System (V2G), Vehicle to Home System (V2H, commonly referred to as a V2X system) to improve EV usability.

- TCS has conducted feasibility studies on the implementation of V2X systems in five countries in Europe and the United States. We use the results of such studies to support EV manufacturers. The survey requirements are as follows:

Full review of National / Regional Power Infrastructure
Full study of Laws, Regulations, Standards and Certification
Development of V2X System Configuration
Understanding Power Conditioning System (PCS) Manufacturers and Local Scenarios

Conclusion

TCS has been leveraging its presence in 50+ Countries in supporting the Major EV OEMs launching their EVs Worldwide overcoming the Language Barriers in non-English Speaking Countries. The TCS’s Agile based Phased approach of accomplishing its 3 Objectives to ensure a Safe & Reliable EV Charging has enabled EV OEMs to launch their EVs Worldwide Briskly with TCS enriching itself with new Challenges when undertaking EV Infrastructure related Activities for newer Countries. For some of the Local Installers, the TCS approach regarding Installation Manual Concept might be Time Consuming but as an end result, till now, this TCS Approach has been able to achieve the Objective of Safe & Reliable Charging bringing Comfort among the Customers by becoming one stop shop solution benefitting all the stakeholders.

*The information shown is as of May 2023.

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