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We make a charging station for electric vehicles from available industrial components.

We make a charging station for electric vehicles from available industrial components.

The topic of electric vehicles and charging stations is one of my favorites, I have been interested in it for a long time and now in connection with the beginning of the active introduction of electric transport, it turns out to practically participate in various projects for the development of charging infrastructure. In the previous overview (link at the end of the publication), the main standards of electric charging stations for alternating (AC) and direct current (DC) current and the basics of building an infrastructure for group charging were presented. The topic interested readers and potential manufacturers of such stations.

At the same time, most of the questions related to how to create a separate charging station. At the same time, the majority of potential manufacturers of electric charging stations have not previously created such stations and therefore there are a lot of questions.

In this review, in a concise form, I will try to talk about the main components for building a charging station and present a basic specification for practical implementation. While we will not touch on the mythology that has developed around electric vehicles and charging systems for them, this is a topic for a separate review. I will definitely be grateful for your questions in the comments on the topic of electric charging infrastructure and electric vehicles..

The most important and important rule when creating a charging station is to protect a person from electric shock when using a charging station..

To everyone who will develop and produce charging stations, please print this inscription in the largest font and be sure to follow this rule in all actions..

Briefly the main standards of electric charging stations.

There are indeed several standards and they are divided into two large groups – AC and DC charging..

It should be noted here that batteries are always charged with direct current and therefore direct current charging is preferable to alternating current. Although AC charging stations are very simple to manufacture and much cheaper, they cannot provide an

electric vehicle with fast and comfortable charging as the battery capacity grows. Why this happens, we will consider in a separate article..

Modern electric vehicle and its charging possibilities.

Components for building a charging station.

SIMATIC automation components.

Charging station controller: SIMATIC ET 200SP Open Controller + ECC TM Freely programmable SIMATIC Energy Meter applications for standard technical energy metering SIMATIC Energy Suite for load balancing SIMATIC HMI external operator panel SIMATIC RFID reader SIMATIC SITOP power supplies.

Components from Siemens.

Transformers Rectifiers (AC / DC) and converters (DC / DC) PN / CAN gateway for CHAdeMO Relays, contactors, protective devices Ethernet switches.

Other components.

Enclosures, control cabinets Special charging cables, sockets, plugs External equipment for calibration of AC / DC equipment.

Charging station based on SIMATIC general concept.

The main part of the charging station, its brain is the SIMATIC software controller.

Structure of the SIMATIC software controller for the charging station.

Why software controller?

Everything is logical here, the charging station requires not only complete, continuous and independent control of the charging process, which can be provided by the SIMATIC software controller with a powerful hypervisor from SIEMENS, but also the combination of these functions with the ability to use third-party applications (for example, in C # / ++) to build backend communication, for example, for billing, user identification, interaction with other systems.

Why using decentralized solutions based on SIMATIC ET200SP?

This is a very comfortable and convenient solution that allows you to create simple configurable solutions with a very high degree of modularity with minimal programming and scaling costs and a minimum of communications..

Technological modules for charging systems of electric vehicles TM ECC.

TM ECC used in conjunction with SIMATIC ET200SP ensures compliance with all charging process standards.

There are two main modules for charging control:

TM ECC 2 x PWM 6FE1242-6TM10-0BB1.

TM ECC 2 x PWM for AC charging 6FE1242-6TM10-0BB1.

Control of 2 AC charging points, power: 11/22 kW (max. 43 kW)


And SIMATIC ET 200SP TM ECC PL ST for DC charging 6FE1242-6TM20-0BB1.

Control of 1 DC charging point, power: 50kW, 120kW and more depending on the charging system.


Highly protected outdoor operator panels, allow use in natural daylight with an operating temperature range of -30 to +60°C.

Industrial Ethernet switch.

Wide range of industrial Ethernet switches with temp range. from -30 to 60 ° C and protection from IP20 to IP67 in both standard and SIPLUS Extreme versions.


Supports ISO 15693 and ISO 14443 A / B (MIFARE) standards DLL for connecting to Windows computers Fully compatible with PM LOGON Basic and Premium Compact slim design and flexible cable with USB connection 3-color indication at the front High degree of protection (IP65 at the front ) and extended temperature range (from -25 ° to + 55 ° C)

SIMATIC ET 200SP Energy Meter.

Record of all necessary measurements Values: U, I, f, S, Q, P, Cos?,?, E. Saving the charging log.

Important! Designed to measure alternating current.


Gateway for connection via Profinet to the CAN infrastructure, configuration in the TIA Portal, design in the style of SIMATIC S7-1200.

There are various options:

PN / CAN LINK PN / BACnet LINK PN / M-Bus LINK PN / J1939 LINK (CAN-based)


SINAMICS DCP is a special bi-directional DC / DC converter with undervoltage and undervoltage. Designed for backup power systems with batteries, alternative energy systems (for example, solar power plants) and charging systems for electric vehicles.

6RP0010-1AA32-0AA0 – 120 kW, 200 A at 600 V, voltage variation from 30V DC- 800V DC 6RP0000-0AA25-0AA0 – 30 kW, 50 A at 600 V, voltage variation from 30V DC- 800V DC.

Basic architecture of DC charging station.

The basic architecture of the DC charging station presented shows the structure of the main components and their basic relationships for the charging station. It should be noted here that the charging station can have various additions and functionality, so the structure can be expanded and supplemented with various other components..

Specification for 240 kW charging station.

This specification is one of the options provided as an example. The specification does not specify communication equipment for validation and identification, as well as wireless communication with cloud billing applications.

Switching equipment specification.

Control system specification based on SIMATIC software controller and ET200SP + communication.

Power component specification.

Important! In the power section, industrial 600V SINAMICS ALM power supplies and 7 DCP modules are represented as rectifiers, DCP modules can operate on the load in parallel, can be connected to the required power.

It should also be noted that the power section, the most expensive and heaviest, by weight, is the part of the charging station. For example, each 120 kW DCP module weighs about 100 kg. In principle, powerful power devices are always expensive and weigh a lot. In the example of the power component specification, a rather expensive but highly functional option is presented, taking into account the use of, for example, peak batteries.

Therefore, it is the power unit that is the basis for interesting solutions and optimization of the cost of the charging station..

Cost allocation in the charging station.

For obvious reasons, I do not have the opportunity to present the price of components and the cost of the charging station, but if we use the basic affordable prices without taking into account discounts and the cost of the shell (electrical cabinet), charging cable (and this is a very expensive cable, and at a power of about 100 kW and above, it is required liquid-cooled cable), connectors.

That cost distribution in some approximation will be as follows:

Low voltage switching – 12% Control system (PLC + ET200SP components + internal communication) -10% Power section – 78%

Conceptual Framework for Custody Transfer Calibration and Certification.

The concept of calibration is in principle simple, but note that the certification of a specific station is done when necessary and there are other options..

Subject to change! Not a complete solution!

Submit your application and receive a very profitable commercial offer for Siemens equipment within 4 hours.

Send an application and receive a commercial offer for Siemens equipment.

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