Building Charging Systems for Electric Vehicles

Charging systems are used in many different settings to power electric vehicles. They can be built for a number of purposes, from overnight charging to high-speed charging for long-distance travel. This blog will discuss the growing need for efficient EV charging systems and detail the types of EV charging systems users can choose from.

Importance of Charging Systems for Electric Vehicles

As the number of electric vehicles on the road increases, so does the need for efficient EV charging systems. Having reliable access to charging systems provides added convenience and flexibility for EV owners. It also removes fossil fuels from the equation, which is essential to achieving long-term sustainability goals and supporting the continued adoption of electric vehicles.

Types of EV Charging Systems Explained

When building charging systems for electric vehicles, there are two primary challenges to address. The first is logistics, with many consumers expressing a desire for more charging stations. As of now, there are far fewer charging ports than are needed to achieve carbon-free energy systems by 2050.

The second issue involves concerns regarding travelable distance with each charging cycle. Currently, several main types of charging systems are available for electric vehicles:

• Level 1. These are slower systems that many homes use to charge vehicles overnight, with each hour of charging supplying enough power for a five-mile driving range.
• Level 2. Many public facilities and workplaces use these faster chargers, which supply enough charge every hour for 25 miles of range.
• Level 3. Ideal for gas stations and other locations accommodating long-distance travel, these are the fastest chargers, supplying sufficient power for up to over 200 miles of range after 30 minutes of charging.

Building high-quality electric vehicle charging stations promotes a strong charging infrastructure that can meet the varied needs of EV vehicles.

What Makes up an EV Charging System?

Electrical vehicle charging systems rely on a number of components, connectors, and systems:

Power Sources and Compatibility

Charging systems need to be able to draw power from reliable sources and must work with multiple types of EVs. The electric grid is a primary source for EV power. Power lines in the grid transmit electrical power to charging stations, transitioning the power into direct current (DC) electricity to supply the charge.

Due to the external installation of many charging stations, power sources often require an EV power distribution cabinet. This provides ongoing protection from harsh weather and other environmental conditions.

Connectors and Cables

Charging systems typically use one of two types of connectors:

• Alternating current (AC) connectors for slower chargers running on AC
• DC connectors for faster chargers using DC

In North American markets, you can obtain two primary charger plug types, including CCS 1 for DC charging and SAE J1772 (Type 1) chargers for Level 1 and 2 AC charging.

Software and Monitoring Systems

These systems also require management and monitoring tools to maintain efficient energy use. Innovations in software allow for intelligent infrastructures that effectively track energy usage. For instance, systems may use cloud-based solutions that offer features like remote real-time monitoring and management or in-depth data analytics. These solutions help meet drivers’ needs while also optimizing the user experience.

Site and Power Requirements

EV charging systems must perform according to several critical requirements:

• Power Requirements. Different electric vehicles will require varying power levels. While most home chargers use up to 7,200 watts (W), this fluctuates based on the charger and charging mode.
• Site Setup Needs. While indoor installation will provide better protection from the elements, some may prefer outdoor-rated systems for parking lots and other exterior sites. Regardless of the placement of charging systems, they must connect to a nearby building’s power supply.
• Safety Compliance. Chargers also need to be dependable and safe, from the conductor used during installation to the amount of overhead space they provide. It’s important to consult the manufacturer’s instructions for details about proper usage, storage, and charging, as any unauthorized modifications could render charging systems unsafe.

Charging Systems for Electric Vehicles at H&S Manufacturing

Selecting the best charging station for a given area ultimately depends on build and charging requirements. AT H&S Manufacturing, we are familiar with the evolving charging needs of our customers. We provide custom metal fabrication services for a variety of applications, including automotive, aerospace, electronics, and medical devices.

For help with an EV charging system build, turn to the experts at H&S Manufacturing. Request a quote today to learn more about our capabilities and get started on a custom build.