Electric mobility is among the markets most widely regarded in the public imagination as Green, and its development has yet to reach full maturity. Although problems with microchip shortages and tensions in commodity markets are slowing industry growth and registrations of BEVs and PHEVs, the trend continues to be the focus of media and cultural attention.
As theelectric vehicle market grows, so does the need for a technologically advanced charging infrastructure with a widespread presence within the territory. In fact, the public charging points present in Italy to date are about 30,000 (May 2022) while in other countries such as Germany and France the number is higher (over 63,000 and 55,000 charging points, respectively).
In 2021, Europe saw the largest percentage of electric vehicles sold in the world (19 percent of the total), ahead of even China (15 percent, growing rapidly) and the United States (4 percent). In addition, following the proposal accepted by the European Parliament to eliminate the production of gasoline and diesel vehicles from 2035, it can be expected that the sale of electric vehicles in the EU area will see a surge.
What are the main charging connectors for electric mobility?
Let us then try to explain how electric vehicle batteries are recharged, what components are needed, and what types of charging exist. The cable that usually comes with the vehicle is in fact characterized by a socket and a plug that allow the connection between the vehicle and the charging station.
There are currently four main types of electric vehicle charging plugs, two AC and two DC:
- Type 1: single-phase plug found in electric vehicles from the American and Asian markets; charges the car up to 7.4 kW.
- Type 2: Can be single-phase or three-phase and is the European standard for electric mobility. It allows charging up to 43 kW at public charging stations.
Then there are the chapters of home charging, connecting directly to the home grid (chargers from 3 to 22 kW) and that of fast and ultra-fast charging systems (up to 350 kW).
In the area of rapid and ultra-rapid charging of electric vehicles (EVs), two standards developed by as many electric vehicle manufacturer associations have come to the fore:
- CHAdeMO: a two-way charging system developed by the "Japan Electric Vehicle Fast Charger Association"; initially designed to offer 62.5 kW (125A x 500VDC), it has risen with the 2.0 revision to a maximum of 400 kW (400A x 1kV) and aims to reach 900kW with the 3.0 version.
- CCS: The Combined Charging System (supported by manufacturers such as BMW, Daimler, FCA, Ford, Jaguar, General Motors, PSA, Honda, Hyundai, Kia, Mazda, MG, Renault, Tesla, Tata, and Volkswagen) involves the use of special connectors (Combo 1 and Combo 2) with additional DC power contacts. It is an improved version of the Type 2 plug that provides two additional power contacts allowing charging up to 350 kW (up to 500A and at 920V).
The type 2 connector: the Italian standard
In Italy, the most widespread connector is the Type 2 connector; this solution is now the European standard for AC charging of electric vehicles. It can be used within both single-phase and three-phase systems, and it is precisely because of this versatility that it has spread with great success. The Type 2 connector must provide a system for retaining the plug in the socket and has seven contacts: 5 power and 2 communication.
Power contacts are differentiated in turn into:
- L1, L2, L3: are the phase conductors, where phase is nothing but the electrical wire intended for the passage of current;
- N: is the neutral conductor; it is a zero-potential connector, electrically connected to the center of the transformer that promotes the distribution of electric current. If the neutral of the line supplying the loads on a phase is interrupted, the current is interrupted and the voltage on them cancels;
- PE: is the protective conductor; it makes the connection of the earths with the grounding system. It therefore has the function of conveying fault currents, which may occur on the grounds in case of failure of the insulators or in the earth electrodes placed in the ground.
Communication contacts are differentiated into:
- PP: this is the proximity contact with no special functionality; it provides the information about the charging in progress.
- PC: is the pilot control; it is the conductor through which information for communication is transmitted.
Certifications required for the trade and use of cables and connectors
In addition to CE marking, electric vehicle charging cables and connectors require other specific certifications:
- RoHS certification: legislation 2002/95/EC was adopted by the European Community to impose restrictions on the use of hazardous substances found within electrical and electronic components. Under this directive, manufacturers are therefore required to replace chemicals deemed most hazardous with less impactful alternatives.
- IATF 16949 certification: is a quality standard specifically for the automotive market; it is based on ISO 9001, with the addition of more detailed requirements for the automotive industry. It is a basic prerequisite for being able to develop projects within this market and offers guarantees regarding quality.
- TÜV Certification: is a set of German-originated certifying bodies involved in issuing quality certificates in the areas of safety, product certification, inspection and technical support. Its deep-rooted presence in German and Italian territory, nations with great automotive backgrounds, gives it considerable importance.
