Using the charging technology for electric vehicles safely

AC charging column

Safe charging of electrical vehicles

[] Ladesäule AC-Ladung

AC charging stations can often be found at home, in hotels or at the workplace, as AC charging utilises conventional low voltage. This means AC charging has the benefit that charging infrastructure required can be kept relatively simple. However, the vehicle must have charging electronics which have a weight and volume roughly in proportion to the maximum possible charging power. Whether it is a small board fitted into a mobile charger to detect any faults quickly and safely and provide information and/or switch off if there is a hazard. Or even a somewhat larger series device used in a stationary system. In both cases, Bender fulfils all current standards and the user of the charging station is on the safe side.

Market segment brochure eMobility
Technical paper Charging Electric Vehicles - Protection against Electric Shock by DC Fault Current Sensor Units

Recommended systems for insulation monitoring:

Recommended systems for residual current monitoring:

Recommended Smart-Grid Charge Controller:

  • DIN IEC/TS 61439-7

Charging cable (IC-CPD)

Safe plug-in solution

[] Ladekabel (IC-CPD)

As AC charging involves charging the electric vehicle from the normal outlet at home, the charging infrastructure is simply the charging cable. This special charging cable must have an integrated monitoring system and the vehicle must have internal charging electronics. Bender offers residual current monitoring sensors for mode 2 charging cable manufacturers. These sensors can be used in IC-CPDs in accordance with IEC 62752.

Market segment brochure eMobility
Technical paper Charging Electric Vehicles - Protection against Electric Shock by DC Fault Current Sensor Units

Residual current monitoring:

  • IEC 62752
  • DIN EN 62752

DC charging column

Electrical safety while charging electric vehicles

[] Ladesäule DC-Ladung

Larger charging stations and quick charging stations use DC charging. Generally, this is an unearthed system. DC charging involves passing an external DC voltage to batteries connected in series. In order for current to flow, the voltage must be governed so that it is always slightly higher than the current cell voltage of the batteries connected in series. This involves complex charging control systems as the currents can be up to several 100 A. This process charges the battery up again in around 15 minutes. This concept is ideal for recharging during a journey, at a motorway service station, for example. In order to prevent the insulation monitoring device in the vehicle and the one in the charging column influencing one another, the insulation monitoring device in the vehicle is also deactivated during the charging process. The insulation monitoring device in the charging column then monitors the entire charging current circuit. The Bender products are market leaders and offer a very high level of safety.

Market segment brochure eMobility
Technical paper Charging Electric Vehicles - Protection against Electric Shock by DC Fault Current Sensor Units
  • DIN IEC/TS 61439-7