Lee, Good comments.  You and I could sit and discuss some parts of your 
comments; however, overall I thank we agree.


________________________________
From: Lee Hart <[email protected]>
Sent: Saturday, November 12, 2016 7:23 PM
To: ROBERT
Subject: Re: [EVDL] Cheap L2 charging in parking places: Bolt EV's In Production

ROBERT wrote:
> Lee, I may have incorrectly stated the frequency of the EV1 induction
> charging. I showed the nameplate data as "Charge Port CP7100, 475VAC
> Peak, 22A AC Max, 400 Hz, 6.5 KW Max Output Power, Manf Date July 1996."
> I should have showed "Charge Port CP7100, 475VAC Peak, 22A AC Max, 6.5
> KW Max Output Power. This is the info on the main nameplate.

Hi Robert,

Schott Power Systems made many of the EV1 Magnecharger parts and modules
for GM and Hughes (including the one on the eBay link you provided). I
worked for them at the time, designing battery chargers and power
electronics.

The "400 Hz" you referred to was the maximum AC input frequency. Though
60 Hz was normally used, it could also be used on 400Hz which is found
in some military and aircraft systems. Hughes is a major in these
markets, so it was normal for them to specify 400 Hz on things they
designed.

The Charge Port module in the eBay listing you provided is an example;
it was built by Schott Power Systems. It's basically a rectifier and
DC/DC converter. It takes high frequency AC from the car half of the
paddle transformer, rectifies it, and converts it to the voltage
commanded by the battery charge controller.

The input frequency range for that particular module isn't the same as
all modules. The frequency range varied, depending on the power level of
the particular charging components. That particular one was for 6.6KW.
They ranged from 3KW to 100KW.

The CP7100 Charge Port had the half of the transformer that goes in the
car, along with the associated mechanical parts and shielding. The
rectifier was located in the separate Charge Port controller. Again,
there were different ones, depending on what maximum power level the
setup allowed.

> Lee, I was making the following points in my e-mail concerning the
> installation of a large number of EVSEs in a parking area:
>
> (1) (2) The installation will be very expensive...

Our present EVSE setup is expensive and unreliable. But, it could be
argued that the auto and utility companies *want* an expensive and
unreliable system. It's a way to discourage EVs.

> (3) The system will have a low utilization rate because vehicle will
> be parked for an extended periods

True, if each EVSE is a high-power setup, and gets used in a place where
cars will get parked for long periods of time.

> (4) System security is low because of scammers and no local oversight

I'm not sure there is any real problem with scammers. Around here, we've
had free outdoor AC outlets for 50+ years, and I've never heard of any
problems with people "stealing" power. Sure, a homeless person might
charge their cellphone from one of these outlets; but so what? The power
used is a penny or less -- too small to charge for.

PS: Putting that nice big expensive copper cord on every EVSE is an
invitation for copper thieves. If they only provided NEMA receptacles,
there wouldn't be anything to steal.

> (5) Not a safe system because of a possible pool of water or vandalism.

Well, we've mandated GFCIs for decades on all outdoor outlets. They seem
to solve the safety problems.

PS: Normal GFCI's have a 5ma limit. That's low enough to be safe for
even children and the infirm. The auto companies have pushed for a 20ma
limit instead. 20ma *probably* won't kill a healthy person, but
certainly could a younger or less healthy individual.

> Due to the above points, the installation of a large number of EVSEs in
> a parking area (1) is not an efficient use of equipment, (2) has low
> system security, (3) unsafe system and (4) is not a good use of capital.
>
> My suggestion to solve the problem was for everyone to charge at home
> with a NEMA type outlet or use an induction type system in a parking area.

I'm with you; the present EVSE model is not a good choice for widespread
adoption. Regular NEMA outlets look like a better choice.

> An induction type system reduces the installation cost because of a
> reduction in the size of the electrical distribution system. With an
> induction coupled system, the main source can sense the presence of a
> vehicle or if a vehicle requires power; therefore, the main source can
> be sized to the utilization rate.

In fact, Schott did have a version of our 100KW charger that could
charge multiple vehicles at once. It divided the power between them.

An induction charging system will be *more* expensive than a conductive
one. The Magnecharger was very expensive! But it was virtually
hand-made, and seriously over-designed to high standards. I think that
with mass production and reasonable design standards, a magnetic
charging system could be only *slightly* more expensive than a
conductive charging system. However, it would require tight cooperation
between the car companies to keep them compatible. That is a FAR bigger
problem than the engineering challenges.

> This cannot be done with an EVSE system.

Yes, it can. The regulations didn't expect it, but it could be made to
work anyway.

> The system is safer because it is not effected by water
> and is secure from vandalism.

The safety benefits are dubious, since the conductive systems don't
energize the cable until after the connection is made.

And the Magnecharger cable is just as vulnerable to theft and vandalism.

The best setup is just to have a NEMA receptacle on the "charging
station", and the cord and charger in the EV being charged. Unroll your
own code, and plug it in. If it's stolen, your insurance would cover it
like any other act of vandalism (like a broken window, etc.)

> An X10 system (PowerLine Transmission) will not work in an industrial or
> commercial environment

The consumer-grade X10 was optimized to be cheap, not robust. But there
*are* industrial-grade setups that work over the power line.

> RF is not reliable in a structure with high levels of electrical noise

It's reliable enough for a car parked right next to a charging station,
with nothing but air between them.

--
The reasonable man adapts himself to the world. The unreasonable man
persists in trying to adapt the world to himself. Therefore all
progress depends on the unreasonable man. -- George Bernard Shaw
--
Lee Hart, 814 8th Ave N, Sartell MN 56377, 
www.sunrise-ev.com<http://www.sunrise-ev.com>
The Sunrise EV2 Project<http://www.sunrise-ev.com/>
www.sunrise-ev.com
The Sunrise EV2 Project Homepage. Welcome! We are a group of dedicated electric 
vehicle enthusiasts whose goal is to create an affordable, high performance 
electric ...


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