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Charging Research (11/28/2023) #2

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Charging Research (11/28/2023) #2

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54 changes: 15 additions & 39 deletions .obsidian/workspace.json
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20 changes: 19 additions & 1 deletion Component Research/Charging Research.md
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Expand Up @@ -41,4 +41,22 @@ Elcon HK-J 6.6kW charger:
* HK-J-H198-46: 50-198VDC Max DC output voltage range, 46A Max Current
* HK-J-H440-20: 110-440VDC Max DC output voltage range, 20A Max Current
* HK-J-H650-12: 170-650VDC Max DC output voltage range, 12A Max Current
* Cost ranges across websites, no clear price range, but typically does not exceed 2000 USD
* Cost ranges across websites, no clear price range, but typically does not exceed 2000 USD

**Plan of Action:**
With research on other chargers in mind, the Elcon HK-J 6.6kW seems to be the most viable solution, as others usually limit at 450VDC, meanwhile the accumulator sits at 464VDC. Specifically the HK-J-H650-12 supports the input AC voltage/current supplied by FSAE during competition, and matches the voltage standard our battery limits, that being 464VDC. As such, assuming an order can be made of this charger, all that's remaining is dealing with the charging shutdown circuit, as well as the charging port.

**Charging Port:**
As the level of charging can presumably be concluded to be targeted for level 2 charging (as such is provided by FSAE during competition, and 120V charging is incredibly slow in comparison), the plug required must be the J1772, as stated by the provided charging from FSAE during competition: https://www.fsaeonline.com/cdsweb/gen/DownloadDocument.aspx?DocumentID=07af1b6a-f8ff-45b1-ba5e-1ced61d70d5c
Therefore, a J1772 plug supporting the voltage/current thresholds of 20A and 208V from an AC supply must be accomodated.
The following are two products found from electricmotorsport.com, which may not be an ideal order location, but does show some options for the charger:
* J1772 32A Plug and UL Cable 5m with Dust Cover: https://www.electricmotorsport.com/ev-parts/chargers/j1772/j1772-32a-plug-cord.html
* This charger provides the UL cable connected to the charging port itself
* J1772 32A Receptacle V3 w/ Terminals & Hardware: https://www.electricmotorsport.com/ev-parts/chargers/j1772/j1772-32a-receptacle-ver-2.html
* This charger does not provide the UL cable, and therefore must be developed following purchase
There also exists the Active Vehicle Side Control Board Module, which may be of aid for achieving safety standards declared by FSAE, and/or provide guidance to covering said rules: https://www.electricmotorsport.com/ev-parts/chargers/j1772/avc2-module.html

**Charging Shutdown Circuit:**
[[EV.9.3 Charging Shutdown Circuit]] states the purpose of the development of the charging shutdown circuit. The goal is to use readings from the [[EV.8.3 AMS]] and [[EV.8.6 IMD]] to determine if the charging shutdown circuit must be triggered, which would be when readings are at critical points. In real-world application to EV conversions, it is common to see this being done with the CAN Bus Shunt, which measures readings of current, voltage, and temperature, for BMS systems. See the following of an example item from DigiKey: https://www.digikey.com/en/product-highlight/i/isabellenhuette/ivt-s-current-voltage-and-temperature-sensors
The CAN Bus Shunt may be of good reference to how it may be possible to develop an appropriate for measuring voltage, current, and temperature, while the charging shutdown circuit can be developed around these readings. The Elcon HK-J-H650-12 can be bought with a CAN bus to retrieve information, which may also be integral to the development of the shutdown circuit.
What comes next with the circuit is the development of the model (to be done presumably in Altium), but before this comes discussion and approval from the electrical leads on deciding which options to pursue.