FlexCase

EV Charging

  • Control Pilot & Proximity Pilot
  • Powerline Communication
 

Prerequisites

  • Complete the install guide guide for a tutorial on connecting and flashing binaries
  • Complete the Quick start guide.
  • Familiarity with electrical wiring and basic control signals (CP, PP)
  • (Optional) Familiarity with high-level standards (e.g., ISO 15118, DIN 70121, SAE J1772, IEC 62196) for further software integration

Overview of EV Charging Signals

EV charging communication involves two fundamental pilot signals—Control Pilot (CP) and Proximity Pilot (PP)—used primarily in AC charging, plus more advanced Power Line Communication (PLC) often used in DC fast charging. These signals coordinate charging states, ensure safety, and manage current limits.

  1. Control Pilot (CP)
    • Used to detect the EV, request current limits, and manage charging start/stop.
    • Implements a PWM signal that conveys the allowable charging current and detects the presence of a vehicle.
  2. Proximity Pilot (PP)
    • Primarily indicates the cable’s current-carrying capacity to the EV (e.g., 13A, 32A, etc.).
    • Allows the EV’s onboard charger to safely limit charging based on the cable rating.
  3. Power Line Communication (PLC)
    • Used in DC charging (fast charging) to exchange higher-level data, such as battery state of charge, billing info, and control commands.
    • Usually follows ISO 15118 or DIN 70121 protocols and uses the same DC charging connectors to physically carry the high-level communication signals.

Specifications

A Summary of the specifications is provided below

 

Item Specification
AC Charging

Control Pilot
Measurement via DI
Protections: Over/Under voltage, Short to Battery/GND, Reverse polarity.
Warning: With PLC present voltage rating is reduced to 13V.

Proximity Pilot
Measurement via ADC
Protections: Over/Under voltage, Short to Battery/GND, Reverse polarity.

Standards
IEC 61851 / SAE J1772
DC Charging

PLC
Communication with MCU via SPI.
QCA 7006AQ Chip

Standards
ISO/IEC15118/DIN 70121/SAE J2847/2

*Vehicle inlet resistor is not populated by default on the VCU, but can be configured for volume orders.

Connector Standards

Audesse currently supports various regions and automakers using different connector shapes and pilot signal schemes

  • Combined Charging System (CCS1)

    • Used predominantly in North America.
    • Incorporates the AC J1772 connector with two additional DC pins, supporting both AC and DC charging.
    • Communicates using CP/PP for AC or PLC for DC fast charging.

  • Combined Charging System (CCS2)

    • Popular in Europe and other regions.
    • Uses the Type 2 AC connector with two additional DC pins; also supports both AC and DC charging.
    • Similarly uses CP/PP signals for AC and PLC for DC communication.

  • North American Charging Standard (NACS)

    • Formerly known as the Tesla connector in North America.
    • A streamlined design that supports both AC and high-power DC charging through the same pin layout.

For additional plug support please reach out to our team.

Basic Control Flow

  1. EV Detection: The vehicle is plugged in, and the PP/CP circuits detect presence.
  2. CP PWM: The charging station sets the allowed current based on system capacity; the EV ramps up or down accordingly.
  3. PLC Negotiation (DC only): If using CCS for DC charging, a PLC handshake occurs to authenticate and finalize charging parameters.
  4. Energy Transfer: The station provides AC or DC power to the EV under monitored conditions (voltage, current, temperature).
  5. Termination: The user or EV can request a charge stop via CP transitions or PLC messages.

Software Configuration

  • Proximity Pilot Handling: Be sure to set the 5V sensor outputs to on.
  • Pilot Signal Handling: In the development environment, configure dedicated DI to read PWM signals for CP and can drive chart status pin.
  • PLC Stack Integration: For DC fast charging, integrate an ISO 15118/DIN 70121 (license options available) software stack into main algorithm