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EV Fast-Charging Standards In Flux

savuporo writes "With the first battery electric vehicles becoming available on markets worldwide, there is an increased push to establish standards for fast-charging plugs. Unfortunately, the story is far from simple. The US hopes to establish its own DC fast-charging standard by 2012, and Europe cannot come to an agreement about their version. Meanwhile, the CHAdeMO fast-charge standard developed and widely deployed in Japan, used on both the Nissan Leaf and Mitsubishi MiEV, is gaining momentum with deployments underway both in the US and Europe. CHAdeMO is limited to a 62kW charge rate, able to charge smaller battery packs to 80% SoC in 15-30 minutes."

28 of 122 comments (clear)

  1. For those of you playing at home by Anonymous Coward · · Score: 5, Informative

    For those of you playing at home, SoC stands for 'State of Charge'.

    1. Re:For those of you playing at home by davester666 · · Score: 2

      By bridging the two terminals with your tongue.

      --
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  2. Multiple standards can coexist by hawguy · · Score: 3, Interesting

    There's no reason why an EV refueling station can't support multiple charge standards (as long as there are only a handful versus dozens).

    One of the biggest expenses in setting up a charging station is in getting the high-power high-voltage power feed from the power company. Supporting a different connector or voltage adds a relatively small incremental cost to the charging station.

    After all, gas stations already support diesel and 3 grades of gasoline (ok, technically it's just 2 grades and they blend them at the pump).

    1. Re:Multiple standards can coexist by xMrFishx · · Score: 2, Informative

      As long as you have a Max1KV connector, a Max3KV connector etc you can mix standards. If you have identical connectors you lead to the Petrol in a Diesel tank problem where connecting a substantially higher voltage to a car that can not transform or handle safely, potentially damaging the car's electrical infrastructure.

    2. Re:Multiple standards can coexist by jimicus · · Score: 2

      IIRC it's the other way around, making it harder to mis-fuel a petrol vehicle than a diesel one.

      This doesn't make much sense considering the other way around is substantially more expensive, but there you go...

    3. Re:Multiple standards can coexist by Rei · · Score: 3, Informative

      EV charge connectors are *far* more intelligent than gas nozzles. Ever see an EV charge connector and wondered why there are so many pins? There's sense pins, data pins, etc; there's a bidirectional communication which makes sure the connector is fully secure and that the type of power being delivered is compatible with the vehicle before it is actually delivered.

      --
      Then the winter came, and the Grasshopper died. And the Octopus ate all his acorns. Also, he got a racecar.
    4. Re:Multiple standards can coexist by Chris+Mattern · · Score: 2

      On the other hand, there's a lot more petrol vehicles than diesels ones, so by making it hard to mis-fuel a petrol vehicle you're protecting more vehicles.

    5. Re:Multiple standards can coexist by MBCook · · Score: 2

      This would be a much bigger problem for a home or perhaps a business that wants to have an EV charging station. Just putting one in would be a large expense for a home or say a small local co-op that wants to do something green. Having an EV charging station should help with your home's value (assuming EVs start to take off), but if it's the wrong kind it's just a hassle. It's something that you'd have to replace at a large cost. Or what if I have a Ford EV and my friend comes over and asks if he could charge his VW EV? He can't, because of a standard issue. No quick charge, just the 6 hour trickle from a standard outlet. That won't do him much good, he's not going to be here very long.

      If there was one dominant standard, it would be more reassuring and easier for drivers. It's just one more thing drivers have to think about.

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    6. Re:Multiple standards can coexist by jo_ham · · Score: 2

      In the UK about half of all consumer cars are diesel, right down to tiny little hatchbacks with 7 gallon tanks.

      Truck pumps are also usually separate, since it allows them easier access and exit from the station, and often with no overhead cover so no worry about height issues.

      Certainly if it *was* a flow rate issue it has just been grandfathered in here.

  3. Switch Batteries? by rusl · · Score: 2, Interesting

    Obviously a fast switch of batteries is a better idea. I don't want to wait 15 minutes or even 5 to recharge. Then they can have fast chargers dedicated and efficient to re supply the batteries. I know batteries are expensive so the biggest obstacle is just figuring out a credit/ID system so that people can be trusted to trade $1000 batteries quickly.

    --
    Stupidity is its own reward.
    1. Re:Switch Batteries? by exploder · · Score: 2

      That's great if the batteries are standard and easily accessible. Aren't many (even most?) batteries either built-in or specially shaped for the specific vehicle?

      --
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    2. Re:Switch Batteries? by hawguy · · Score: 3, Insightful

      Obviously a fast switch of batteries is a better idea. I don't want to wait 15 minutes or even 5 to recharge. Then they can have fast chargers dedicated and efficient to re supply the batteries. I know batteries are expensive so the biggest obstacle is just figuring out a credit/ID system so that people can be trusted to trade $1000 batteries quickly.

      I don't think the cost of the battery pack is a factor, nor is verifying credit/ID a difficult problem...I can rent a $25,000 car from a car rental agency in a few minutes -- if I'm in the right car rental membership program, my reserved car is waiting for me in the lot so I just hop in and drive to the gate, then show my driver's license to leave the lot.

      I think a bigger obstacle is that people would have to agree to battery leasing programs instead of ownership. If you own the battery, you're not going to want to swap out your brand new battery with some old worn out battery that happened to be on the shelf at the service station.

      Coupled with the fact that it's even harder to standardize on battery design/voltage than on charging connector/voltage. Physical dimensions of battery packs can vary widely depending on the design of the car.

    3. Re:Switch Batteries? by robot256 · · Score: 4, Insightful

      You don't want to wait 5 minutes for a recharge? It takes longer than that to fuel a gas car. If it were such a big problem they would have invented swappable gas tanks long ago.

      Besides, it's far easier to standardize a plug than an entire battery pack. Car manufacturers would hate the constraint of standardized battery packs--it's much easier to design a usable car if you can shove batteries wherever you want. But it's relatively easy to put any kind of plug on any kind of car.

      It's also one thing for a gas station to have three different plugs at each booth; another thing to stock 10 different kinds of batteries for trucks, SUVs, sport cars, family cars, mini cars, etc etc etc. Not to mention the huge investment in robotic battery changers at all the gas stations--that costs way more than plugs on a rack.

      Don't worry, by the time EVs are common enough for battery swapping to make any sense at all, the batteries themselves will be so advanced they will charge in a reasonable amount of time and it will be unnecessary. In the meantime, we have to put up with the practicalities of boot-strapping an entire market in the face of subsidized competition (petroleum industry).

    4. Re:Switch Batteries? by hernick · · Score: 3, Interesting

      Oh no, these aren't 1000$ batteries we're talking about. A thousand-dollar battery is what you put on an electric bicycle.

      A 16kWh pack (like the Nissan LEAF and Mitsubishi i-Miev use) is about 10 000$. A full charge is good for around 100 miles of autonomy.

      A long-range battery pack would be many tens of thousands of dollars...

    5. Re:Switch Batteries? by black6host · · Score: 3, Insightful

      Obviously a fast switch of batteries is a better idea. I don't want to wait 15 minutes or even 5 to recharge. ...

      How about if the range of the vehicle was quadrupled? Would you wait then?

    6. Re:Switch Batteries? by Rei · · Score: 3, Insightful

      Think of the battery pack like the frame of the vehicle -- huge, heavy, expensive, and critical to the structural integrity of the vehicle. Yes, you *could* make a "hot swappable frame" for a vehicle -- but that doesn't make it a good idea. The frames would be tough to swap, expensive to stock, ridiculously bulky to stock, and as much as you tried to standardize between vehicles, you'd need different models of frames. It's the exact same thing with battery packs. Swapping heavy, structurally-integrity-critical devices with high power, high voltage connectors whose needs in terms of shape, weight distribution, capacity, weight, and voltage discharge profile vary dramatically between vehicles, and which cost many thousands of dollars each to stock... it's just, no. Fast charge is the only realistic way to go.

      --
      Then the winter came, and the Grasshopper died. And the Octopus ate all his acorns. Also, he got a racecar.
    7. Re:Switch Batteries? by tragedy · · Score: 2

      5 minutes? The article summary says that it can charge smaller battery packs to 80% in 15-30 minutes, which we all know actually means at least 30 minutes, probably more, and that's only to 80%, the remaining 20% would probably then take another 30 minutes. As for a regular gas station fillup taking longer than five minutes, that seems a bit of an overestimate (if we assume that we're talking about just the filling time and not also the payment process) considering that typical US gas pumps are up to 10 gallons per minute. Also, considering that gas has about 130 megajoules per gallon, that means that the gas pump pumps up to 1.3 gigajoules of energy in a minute. Divide by 60 and get about 21.7 megajoules per second, which is 21.7 megawatts. As stated in the summary, CHAdeMO is limited to a 62kW, so it's about 1/349th the potential energy transfer rate of a gas pump. There's all sorts of arguments about the actual equivalence of those figures, but the bottom line is that there's still about two orders of magnitude difference between the current and upcoming fast charging standards and what an existing gas pump can deliver. Also, improvements in fast charging are difficult, whereas the design changes to pump gas 10X faster would be relatively trivial.

      The big problem is that we're talking about a lot of energy in a short amount of time. A two minute gas fill up transfers enough stored chemical energy to propel a two ton vehicle at high speed for 500 miles. That's over a period of time about 500 times longer than the fill up took. Add to that, car engines are far, far from 100% efficient, so they produce a lot of waste heat. Compress the time that heat is released in by a factor of 500 and the car doesn't just melt, it partially vaporizes (I think it takes around 4 gigajoules to vaporize two tons of steel starting from room temperature, so not quite enough in a full tank to completely vaporize the car). Batteries are a chemical energy storage mechanism, as is gasoline in an automotive system. When transferring gasoline to a car, the gasoline is kept inert, and no chemical reaction takes place. When batteries recharge, a chemical reaction is taking place inside the batteries. Like the cars gasoline-powered engine, it's far from 100% efficient. Without some unheard of level of charging efficiency, or some amazing heat transfer technology, we're back into vaporize the car (or at least the batteries) territory if the energy is transferred in the same kind of time frame you can fill a gas tank. At the very least, any non-superconducting power cable would certainly vaporize or you'd have to pump the voltage so high it would just arc through the air.

      So, if you can physically transfer your energy in a chemically inert way, there's a clear advantage that battery charging won't be able to overcome unless we develop some really amazing technologies such as room temperature superconductors and superconducting capacitors. Maybe someone can come up with an efficient fuel-able battery that can be recharged by pumping in charged fluid(s). For example sticking with traditional lead-acid batteries, you could pump out lead sulfate nanoparticles (suspended in a conductive liquid medium) and pump in fresh lead oxide and lead nanoparticle suspensions into cathode and anode chambers soaked in sulfuric acid solution and separated with a membrane that lets sulfuric acid and sulfate ions through but not the nanoparticles or the conductive medium. The lead sulfate nano-particles would then go into a similar set of chambers to be charged (converted back to lead and lead oxide through the application of electrical charge while in similar anode and cathode chambers) and later once they're no longer lead sulfate (probably there's a good way to separate lead and lead sulfate as well as lead oxide and lead sulfate nanoparticles chemically or based on density or magnetic/diamagnetic properties or optical properties otherwise, you can just charge the chambers until they're certain to have some particular small percentage of lead sulfate left

    8. Re:Switch Batteries? by tragedy · · Score: 2

      By the same token, pumping gas from an underground reservoir will be a big fail the first time there is a large hurricane evacuation. Because a gas station can run out of gas in the same way that a battery filling station can run out of charged battery. The difference is that, as long as its (very heavy duty) power lines don't go down, the battery filling station can gradually restore its capacity without taking delivery of more batteries. The gas station, once it's out of gas, is empty until a tanker truck arrives. Both the gas filling station and the battery filling station can be refilled by taking delivery from a truck, however.

      It should be noted that, in the case of the battery filling station, the delivery truck has to take away the uncharged batteries as well as delivering fresh, charged ones, and that the batteries will almost certainly be heavier than the equivalent gasoline, so a delivery of batteries will waste a lot more energy than a delivery of gasoline. Except in emergency situations, however, the battery filling station will not need frequent deliveries/pickups, whereas the gas station will. We are talking about an emergency situation here, however, in which case the performance of the battery exchange station doesn't seem to be worse than the gasoline station.

      Also, I think you're misunderstanding the logistics of the situation. Most of the people using a battery filling station are going to be people who are in the middle of a long trip, or who are making a number of shorter trips closer together. Everyone sitting at home or at work (employers might provide it as a perquisite, or they might meter it and charge employees, either way, if electric cars catch on, pretty much every long-term parking spot will have a car charger) is going to have their car charging where it's parked. The default state of an electric car most of the time will be charged. Certainly nearly everyone who needs to go to a filling station is going to be well on their way to their destination rather than near their source. People being evacuated will be near their source and will therefore most likely be fully charged unless it's an area where everyone has a long commute to and from work and the evacuation order is given right around the time everyone is getting home from work. There could also be a problem if there's just one super-long stretch of highway to get out of the evacuation zone that everyone will follow rather than just spreading out in all directions. In that case, the filling stations along that route could get swamped. Once again, this applies equally to gas stations and battery stations. In cases like that, it's the responsibility of emergency agencies to work with the companies behind the filling stations and make sure they're prepared for the extra load. It's a logical part of basic emergency planning. Not that I actually believe that those agencies will actually do this. It will actually take several days of a hundred thousand people sleeping in their cars on the side of the highway for a few days before they'll actually do anything, but that will be true whether the cars are gas or electric.

    9. Re:Switch Batteries? by tragedy · · Score: 2

      Hmm, yeah I guess the Florida keys and Florida itself is a worst case scenario type of situation for that sort of problem. Rather than being able to fan out roughly 180 degrees and get away from a limited evacuation area, you have pretty much one direction to go and, since in some cases the evacuation area could potentially be pretty much the whole state, you have a long way to go so you need to stop to fuel up even if you started with a full charge.

      On the other hand, an emergency situation is a government concern, not one necessarily for the free market to resolve. The government already puts a lot of effort and money into making sure that oil keeps flowing and is available (federal oil reserve, current ongoing wars, and a lot of more mundane infrastructure expenditures). In theory, if an electric and battery distribution infrastructure becomes vital due to electric cars taking over, the government will spend less on supporting the oil infrastructure and more on the electric infrastructure. So, either the government subsidizes greater battery storage and charging capacity and a larger number of batteries than is needed 99.9% of the time or makes sure that they can be delivered when needed. You mentioned a pipeline for delivering fuel to storage tanks. The thing is, with a big enough pipeline and batteries packed in cylinders you could deliver fuel along a pipeline. You don't have to actually do that, of course, but the point is that, once you're treating charged batteries the same way you treat units of liquid fuel, you can set up infrastructure to make batteries just as available as liquid fuels.

    10. Re:Switch Batteries? by MJMullinII · · Score: 2

      So what.

      Burning the dirtiest form of coal in the oldest, dirtiest coal-fired power plants is STILL more efficient than every single person burning gasoline in their tiny engines (I don't care how big your motor is, it is tiny compared to a power plant of any size).

      --
      "Don't be a martyr -- BE THE ONE WHO GOT AWAY!"
  4. Re:Why don't you just by hawguy · · Score: 2

    Why don't you just shove the Japanese plug up your arse and turn it on full current. Why would we want foreign plugs?

    Because they work well with our foreign cars?

  5. International standardization trivial by evilviper · · Score: 4, Interesting

    Honestly, all that matters is that each region has a uniform standard, and is large enough that economies of scale will kick in.

    You're unlikely to take your car to Japan with you, and what's more, since we're only really talking about SIGNALING, it's only going to take a few dollars worth of electronics to do the conversion. Sure, a $20 adapter so you can use your electric razor on another continent is inconvenient, but a $20 adapter so you can use you CAR? No problem.

    Now, if the EU can't agree on a standard, that would be a problem. Wander across the border from Germany to France and you can't charge your car... Oops. And the added expense for charging stations to maintain two or more sets of chargers for different countries' vehicles wouldn't be cheap or easy to maintain.

    Come to think of it... Are electric cars and hybrids coming with normal electrical outlets installed? 120/240V ? They really should. Could eliminate the "car adapter" market over-night, make traveling much easier and add a tremendous amount of utility to an electric vehicle... Even if utility power goes out, EVERYONE with an electric car could have a substantial backup. I can imagine lightning fast tire changes if you can power your impact tools on the road... But I digress.

    Estonia will install approximately 250 quick-charge stations

    As they say, as goes Estonia, so goes Lichtenstein! Clearly Japan is on course to dominate the world...

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  6. They should follow the lead of USB by fotoguzzi · · Score: 4, Funny

    When it comes time to design the plug, they should make sure it's non-tapered so that it has to be perfectly lined up to go in the socket. It should also be perfectly symmetrical so it takes ten minutes get it in the socket correctly.

    --
    Their they're doing there hair.
  7. Re:Switch Batteries? - Power Requirements by bromoseltzer · · Score: 2

    There's another reason that switching batteries is good. If a 62 kW supply is required to charge a battery in 30 minutes, you would need 360 kW+ to charge it in 5 minutes. That's a phenomenal power level. If your charging efficiency is 90%, that means you will be dissipating 36 kW in your car as heat while charging. That's pretty close to explosive.

    The service station and the power utility would have an interest in leveling their load, so charging an inventory of batteries relatively slowly is a good thing. Even so, each recharging station might need a flywheel energy storage unit (or comparable) to even their load on the utility.

    --
    Fiat Lux.
  8. Re:Reinventing the wheel. by PPH · · Score: 3, Insightful

    Because then you might plug your car into any generic 3 phase outlet instead of the one dedicated to vehicular charging with the built in road tax metering.

    --
    Have gnu, will travel.
  9. Re:Switch Batteries? - Power Requirements by Rei · · Score: 2

    1) Li-ion battery packs are generally 96% to over 99% efficient during charging, not 90%.
    2) 36kW is not "pretty close to explosive". That's the heat output of a moderately large home's furnace. You really think you can't simply water quench the output of a home furnace for a couple minutes?
    3) You don't have to draw a rapid charge straight from the grid. A much more reasonable approach is to charge a shared battery bank at the station, and the battery bank discharges the proper amount whenever someone hooks up. Said batteries can be heavy and cheap instead of light and expensive, and are effectively a "universal standard" instead of requiring the station to stock a separate pack for each vehicle profile.

    --
    Then the winter came, and the Grasshopper died. And the Octopus ate all his acorns. Also, he got a racecar.
  10. Re:Minor problem by Rei · · Score: 3, Informative

    LOL. Okay, let's start from the very beginning.

    1) Oil makes up a tiny percentage of our electricity generation -- low single digits. Most incremental power in the US these days (new capacity being added) is natural gas and wind.

    2) According to a PNL/DOE study, 84% of our vehicles could be switched over today without building any new power plants. The reason is because most EV charging is done at night, when we have huge surplus generation capacity

    3) There is little to no need for new bulk distribution, for the same reason as #2. Only local distribution infrastructure may need upgrades when there's high penetration in particular neighborhoods for home charging.

    --
    Then the winter came, and the Grasshopper died. And the Octopus ate all his acorns. Also, he got a racecar.
  11. Re:Minor problem by Rei · · Score: 2

    1) Not "nearly all"; it's about 2/3rds.

    2) Hawaii has 1.3 million people. The US has 300 million people. It's a tiny fraction of the US population. In the US, only Hawaii, the outlying islands, and remote parts of Alaska and the a few remote spots in the desert southwest run on oil-fired power. It makes up 1.6% of our total mix. Why? It has nothing to do with the environment; oil-fired power is very expensive. The only thing oil has going for it is that it's easy to get to remote locations, and hence, its used in places like Hawaii and the remote parts of Alaska.

    3) Gee willickers, wind farms from the 1970s and 1980s are being decommissioned? Who would ever have guessed that power plants built with technology that has been surpassed many times over could be cheaper to replace than to maintain? Thank god some of those ancient relics are finally getting decommissioned; not only are they expensive and failure prone, but they're often sited poorly and are often bird killers (Altamont Pass in particular). If you were trying to design a raptor cuisinart, designing turbines the way they did for Altamont and placing them in that location would be the way to do it. Anyway, as for the failure rate itself, if you want, I can dig up my spreadsheet of turbine data from the Netherlands, where they documented every turbine in the country and its status. The overall failure rate is extremely low. (and tends to follow a bathtub curve), and the older turbines were *much* less reliable than the modern ones.

    4) The wind PTC is under 2 cents per kWh. The estimated health cost from coal power plant emissions, according to the last study I read, ranged from 2 cents to 14 cents per kWh, depending on the plant. *Not* counting climate change, mining consequences, or anything of that nature -- purely airborne emissions.

    5) Photovoltaic solar is too expensive for general purpose power generation, but there are many situations individuals or companies can find them in where it's a big cost saver, even without credits. A reasonable installation cost and $2/wh panels in the desert southwest, for example, can produce a good IRR versus commercial or residential rates. The new generation of solar thermal is much cheaper than oil-fired power (some companies claim they'll be able to reach coal parity like wind has in a few places already, but I think that's yet to be proven).

    --
    Then the winter came, and the Grasshopper died. And the Octopus ate all his acorns. Also, he got a racecar.