Abstract

Recent years have denoted an unexpected, but positive,increase of Electric Vehicles (EV) registrations in Europe, North America, China and Japan. New policies and regulations are pushing the automotive market to develop a robust and reliable electric mobility network: from its charging network infrastructure to the development of new electric vehicles. Many Original Equipment Manufacturers (OEMs) have launched (or are planning to) new electric vehicles to the market, showing a real commitment towardsthe electric revolution the future is expected the world to come. With a focus on Germanyand its current State-of-the-Art regarding EV Charging Infrastructureand EV registrations, public charging equipment seems not to be in accordance with the EV sales increase. Manufacturers and OEM are opting for developing its self-developed charging equipment (so AC Charging Stations), focusing on relieve the stress feeling the drivers have. This Thesis has as objectives to study the State-of-the-Art of the current solutions of 2x22kW AC Charging Stations that complies with the German Calibration Law, summarize the most relevant standards and regulations in order to develop a reliable AC EV Charging Station, list the requirements needed in order to produce a dual 22kW AC Charging Station and propose a solution according the mentionedlist. In order to propose an electrical-safe and competitive AC Charging Station, a market analysis of the current solutions is needed. Moreover, the understanding of the regulations and standards that definewhether an AC Charging Station is qualifiedto be placed in publicand/or private spaces is essentially necessary. Listing all the relevant points of the central documents and comparing it to the current solutions,gives the reader a valuableoverall view of the key points to develop a Charging Pillar. The results demonstrates a “Proof of Concept” for a 22kW AC Charging Stations, centering the solution on the thermal, mechanical and electrical requirements. Using standardized and approved components for electrical safety and charging infrastructure, the solution avoids possible technical disputeswhen validating the AC Charging Infrastructure. Concluding with the strategy that has been adopted, the solution of including all the electrical components inside a box ("IP44) avoids the designing issues it may take to develop a one housing solution. In addition, using standardized components increases significantly the development cost, which it tempts to start considering, in example, the idea todesign a self-developed charging controller

Abstract

The iBooster Gen2 is currently commercialized in three different motor versions: size1, size1+ and size2. Each motor size generates a maximum torque which corresponds to a maximum support force required to slowdown the vehicle. In all these configurations the material of the Valve Body is PET50GF. The possibility of future size3 motors leads to a decrease of the system reliability below of the safety requirements. Therefore, the goal of this project is to identify a new plastic material for the Valve Body able to withstand the size 3 load collective of the iBooster Gen2 without changing the geometry of this part.