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SAE J1772

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SAE J1772
File:SAE J1772 plug and receptacle.jpg
Yazaki's SAE J1772 compliant electric vehicle connector.
Type Automotive power connector
Production history
Manufacturer Yazaki and others
Produced 2009
General specifications
Pins 5

SAE J1772 is a North American standard for electrical connectors for electric vehicles maintained by the Society of Automotive Engineers and has the formal title "SAE Surface Vehicle Recommended Practice J1772, SAE Electric Vehicle Conductive Charge Coupler”.[1] It covers the general physical, electrical, communication protocol, and performance requirements for the electric vehicle conductive charge system and coupler. The intent is to define a common electric vehicle conductive charging system architecture including operational requirements and the functional and dimensional requirements for the vehicle inlet and mating connector.

History

The main stimulus for the development of SAE J1772 came from the California Air Resources Board. Formerly electric vehicles like the General Motors EV1 had used inductive charger couplers. These were ruled out in favor of conductive coupling to supply electricity for recharging with the California Air Resources Board to settle on the SAE J1772-2001 standard[2] as the charging interface for electric vehicles in California in June 2001.[3] Avcon manufactured a rectangular connector compliant with the SAE J1772 REV NOV 2001 specification that was capable of delivering up to 6.6 kW of electrical power.[4]

The CARB regulation of 2001 mandated the usage of SAE J1772-2001 beginning with the 2006 model year. Later requirements asked for higher currents to be used than the Avcon connector could provide. This process led to the proposal of a new round connector design by Yazaki which allows for an increased power delivery of up to 16.8 kW delivered via single phase 120–240 V AC at up to 80 amperes. In 2008 the CARB published a draft amendment to section 1962.2 Title 13 that mandated the usage of the oncoming SAE J1772 standard beginning with the 2010 model year.[5]

The Yazaki plug that was built to the new SAE J1772 plug standard successfully completed certification at UL. It is only certified to 30A although the standard is written to 80A.</ref> The standard specification was subsequently voted upon by the SAE committee in July 2009.[6] On January 14, 2010 the SAE J1772 REV 2009 was adopted by the SAE Motor Vehicle Council.[7] The companies participating in or supporting the revised -2009 standard include GM, Chrysler, Ford, Toyota, Honda, Nissan, and Tesla.

The SAE J1772-2009 connector specification has been added to the international IEC 62196-2 standard ("Part 2: Dimensional compatibility and interchangeability requirements for a.c. pin and contact-tube accessories") with voting on the final specification to close in May 2011.[8] The SAE J1772 connector is considered a "Type 1" implementation providing a single phase coupler.[9]

As of February 2010, the SAE J1772 committee is continuing the standardization process with designing a level 3 connector with additional DC and ground pins.

Properties

Connector

The connector is designed for single phase electrical systems with 120 V or 240 V such as those used in North America and Japan.

The round 43 mm diameter connector has five pins, with 3 different pin sizes

  • AC Line 1 and AC Line 2 - have same size power pins
  • Ground Pin
  • Proximity Detection and Control Pilot - have same size pin

Proximity Detection - Prevents movement of the car while connected to the charger.

Control Pilot - Communication line used to coordinate charging level between the car and the charger as well as other information.

The connector uses a 1 kHz square wave at +/- 12 volts generated by the EVSE on the pilot pin to detect the presence of the vehicle, communicate the maximum allowable charging current, and control charging.[10] The connector is designed to withstand up to 10,000 connection/disconnection cycles and exposure to all kinds of elements. Approximating one connection/disconnection cycle daily, the average connector's lifespan should be just over 27 years.

Charging

In the initial standard, two charging levels are defined.[7]

Voltage Phase Peak current
AC Level 1 120 V Single phase 16 A
AC Level 2 240 V Split phase 32 A (2001)
80 A (2009)

Work continues on specifications for higher-voltage, DC Fast Charge charging,[7] which has been referred to as level 3 charging.

As of February 2010, the SAE J1772 committee is designing a DC connector based on the SAE J1772 AC connector with additional DC and ground pins, to then evaluate against other designs including the JARI/TEPCO connector used by the CHAdeMO DC fast charge protocol.[11] There are indications SAE is also investigating a third level of AC charging.[12]

Safety

The J1772 standard includes several levels of shock protection, ensuring the safety of charging even in wet conditions. Physically, the connection pins are isolated on the interior of the connector when mated, ensuring no physical access to those pins. When not mated, J1772 connectors have no voltage at the pins,[13] and charging power does not flow until commanded by the vehicle.[11]

The pins are of the first-make, last-break variety. So that if the plug is in the charging port of the vehicle and charging, and it is removed, the Control Pilot and Proximity Detection pins will break first so that the Power Pin relay in the Charging Station will be shut off and no current will flow.

Signaling[11]

  • Supply equipment signals presence of AC input power
  • Vehicle detects plug via proximity circuit (thus the vehicle can prevent driving away while connected)
  • Control pilot functions begin
    • Supply equipment detects plug-in electric vehicle
    • Supply equipment indicates to PEV readiness to supply energy
    • PEV ventilation requirements are determined
    • Supply equipment current capacity provided to PEV
  • PEV commands energy flow
  • PEV and supply equipment continuously monitor continuity of safety ground
  • Charge continues as determined by PEV
  • Charge may be interrupted by disconnecting the plug from the vehicle

Compatible vehicle models

Compatible charging stations

The Chevrolet Volt,[18] Nissan Leaf,[19] and smart electric drive all come with 120V portable charging leads that couple a 120V mains plug to the car's J1772 receptacle. For 240V charging, the U.S. National Electrical Code require a coupler to be permanently wired to an AC outlet in most cases;[20] such a coupler is commonly called a charging station. Products compatible with SAE J1772-2009 include:

  • AeroVironment home charging station for the Nissan Leaf[21]
  • ClipperCreek CS-40[22]
  • Coulomb Technologies CT2100 family of charging stations[23]
  • EATON [1] Pow-R-Station Family of Electric Vehicle Charging Stations [2]
  • ECOtality Blink home wall-mount and commercial stand-alone charging stations[24][25]
  • GE Wattstation available in 2011[26]
  • GoSmart Technologies ChargeSPOT line of charging stations
  • GRIDbot's "UP" family of networked charging stations are UL listed and made in the USA. They are designed for multi-family-residential, work-place, retail-parking, city-street, and fleet charging locations.
  • Leviton evr-green home charging stations at a range of power levels, with separate pre-wire kit that allows one to plug in to a NEMA 6 240V receptacle[27]
  • Schneider Electric / Square D EVLink Charging Solutions for residential, commercial, and fleet charging solutions.
  • SemaConnect ChargePro Charging Stations
  • Shorepower Technologies ePump line of fully customizable EVSE; indoor and outdoor solutions for cars and trucks.
  • TucsonEV [3] J1772 Adapter Box, Inlets and Plugs with and without cord, 70A

Competing standards

The proposal of the Mennekes connector initiated by RWE and Daimler has been added as a "Type 2" implementation to IEC 62196 providing a single and three phase coupler.[9][28] The connector was specified in the VDE-AR-E 2623-2-2 standard - this connector specifies up to 63A three-phase (at 400V in Central Europe) which makes for a maximum of 63A*400V*√3 = 43.6 kW. Additionally the IEC 62196-2 standard specifies a "Type 3" connector providing a single and three phase coupler with shutters which takes up the proposal of the EV Plug Alliance (Scame, Schneider, Legrand).[9] All plug types - including Type 1 (SAE), Type 2 (VDE) and Type 3 (EVPlug) - share the same specifications for the pilot pin taken from the IEC 61851-1 standard.

Tokyo Electric Power Company has developed a specification solely for level 3 high-voltage DC automotive fast charging using a different connector (JARI Level 3 DC), and formed the CHΛdeMO (stands for Charge and Move) association with Japanese automakers Mitsubishi, Nissan and Subaru to promote it.[29]

References

  1. ^ Society of Automotive Engineers (2001-09-27). "SAE Electric Vehicle Conductive Charge Coupler, SAE J1772, REV. MONTH01" (DOC). California Air Resources Board. Retrieved 2009-10-23. {{cite journal}}: Cite journal requires |journal= (help); Unknown parameter |coauthor= ignored (|author= suggested) (help)
  2. ^ "Rulemaking: 2001-06-26 Updated and Informative Digest ZEV Infrastructure and Standardization" (PDF). title 13, California Code of Regulations. California Air Resources Board. 2002-05-13. Retrieved 2010-05-23. Standardization of Charging Systems
  3. ^ "ARB Amends ZEV Rule: Standardizes Chargers & Addresses Automaker Mergers" (Press release). California Air Resources Board. 2001-06-28. Retrieved 2010-05-23. the ARB approved the staff proposal to select the conductive charging system used by Ford, Honda and several other manufacturers
  4. ^ California Air Resources Board. "Rulemaking: 2001-06-28 15 DAY NOTICE ZEV Infra 15day Ntc2-28.doc" (PDF). Retrieved 2009-10-23. {{cite journal}}: Cite journal requires |journal= (help); Unknown parameter |coauthor= ignored (|author= suggested) (help)
  5. ^ "Report on the Current Situation and Future Direction of Electric Vehicle Charger Standardisation", SMMT, July 2010
  6. ^ Sam Abuelsamid (2009-06-29). "Underwriters Laboratories approves SAE J1772 charging plug". Retrieved 2009-10-10. Underwriters Laboratories has completed its certification testing on the connector developed by Yazaki. {{cite web}}: External link in |author= (help)
  7. ^ a b c d "SAE standard on EV charging connector approved". SAE International. 2010-01-15. Retrieved 2010-03-14.
  8. ^ "Document: 23H/250/CDV - : IEC 62196-2 Ed. 1: Plugs, socket-outlets, vehicle connectors and vehicle inlets - Conductive charging of electric vehicles - Part 2: Dimensional compatibility and interchangeability requirements for a.c. pin and contact-tube accessories", IEC, 13. December 2010
  9. ^ a b c "IEC International Standard for EV charging - A step forward for global EV roll-out", IEC Newslog, 3. February 2011
  10. ^ SAE EV Charging Systems Committee, SAE Electric Vehicle Conductive Charge Coupler
  11. ^ a b c Gery Kissel, SAE J1772 Task Force Lead (2010-02-18). "SAE J1772 Update For IEEE Standard 1809 Guide for Electric-Sourced Transportation Infrastructure Meeting" (PDF). SAE International. Retrieved 2010-09-03.{{cite web}}: CS1 maint: numeric names: authors list (link)
  12. ^ David Herron (2010-07-30). "Electric vehicle charging standards". V is for Voltage Forums. Retrieved 2010-08-19. {{cite web}}: External link in |publisher= (help)
  13. ^ "Charging the Chevy Volt web chat". GM-Volt.com. 2009-08-20. Retrieved 2010-09-03. When a J1772 standard plug (like on the Volt) is disconnected from the vehicle, no voltage is present at the pins. {{cite web}}: External link in |publisher= (help)
  14. ^ Brian Verprauskus (2010-03). "Nissan's Zero-Emission Future" (PDF). Nissan North America. Retrieved 2010-06-22. {{cite web}}: Check date values in: |date= (help)
  15. ^ "REV ACX 300".
  16. ^ "J1772 Mobile Connector". Tesla Motors. Retrieved 13 May 2011.
  17. ^ Blade, Ross. "Specifications". BEV.
  18. ^ Sebastian Blanco (2009-08-11). "GM shows off 120V and 240V chargers for 2011 Chevy Volt". Autoblog. Retrieved 2010-06-27.
  19. ^ "Nissan LEAF Electric Car | Answers | Charging". Nissan. Retrieved 2010-05-25.
  20. ^ "NEC 1999 National Electrical Code Article 625 - Electric Vehicle Charging System". National Electrical Code. 1999. Retrieved 2010-06-27.
  21. ^ Patrick Ponticel (2010-01-15). "AeroVironment to supply Leaf home charging unit". SAE Vehicle Engineering Online. SAE International. Retrieved 2010-06-26.
  22. ^ "ClipperCreek Ships the Only UL Listed SAE Compatible Charging Station" (Press release). ClipperCreek. 2010-05-07. Retrieved 2010-06-26.
  23. ^ "Coulomb Technologies Achieves UL Listing from Underwriters Laboratories for ChargePoint Networked Charging Stations for Electric Vehicles" (Press release). Coulomb Technologies. 2010-06-09. Retrieved 2010-06-26.
  24. ^ Donald Melanson (2010-07-27). "ECOtality and Frog Design debut eye-catching Blink EV chargers". Engadget. Retrieved 2010-07-29.
  25. ^ "ECOtality Introduces Blink The First Smart, Interactive, Iconic EV Chargers and Network" (PDF) (Press release). ECOtality. 2010-07-27. Retrieved 2010-07-29.
  26. ^ Sebastian Blanco (2010-07-13). "GE unveils new electric car charger, the WattStation [w/video]". Autoblog Green. Retrieved 2010-07-13.
  27. ^ "Leviton Announces Residential Charging Stations for Electric Vehicle Market" (Press release). Leviton. 2010-07-20. Retrieved 2010-07-29.
  28. ^ Winfried Tröster (2009-01-29). "62196 Part 2-X: Dimensional interchangeability requirements for pin and contact-tube vehicle couplers" (PDF). International Electrotechnical Commission. Retrieved 2010-04-15.
  29. ^ "Tokyo Electric Power Licenses Aker Wade to Build Level III Fast Chargers". Green Car Congress. 2010-01-15. Retrieved 2010-04-13.
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