How connection technology is driving the expansion of AC charging points for e-mobility

E-mobility is crucial for a sustainable future in the All Electric Society. However,its acceptance depends on abundant charging points, low maintenance costs, and short charging times. Therefore, electrical connection technology is key to enhancing these aspects.

Moreover, global demand for charging points is rising, with both AC and DC charging being essential. Specifically, AC charging, suitable for long parking periods, is done via home or public stations, while DC charging offers faster charging of the vehicle battery, necessary for long trips.

The AC to DC charging point ratio is about 10:1, and Europe will need over 30 million new AC points by 2030. Connection technology is crucial for cost-effective and reliable AC charger operation.

Cost-effective and reliable AC charging points

In modular charging stations, components like the power supply and AC charging controller are often manually mounted on DIN rails, which is time-consuming and costly, and prone to errors. Incorporating more functions directly on the PCB reduces manual wiring, error rates, and makes home chargers more compact and cost-effective.

Fast and reliable installation on site

An 11 kW charging point in Europe costs about 1,375 euros, with installation making up nearly 30% of this at 375 euros. Specialists installing these points are often under time pressure and can only briefly view instructions.

Intuitive fast-connection technology is advantageous for home charger installation, especially with three-phase connections. PCB terminal blocks with lever connections simplify and speed up the process, ensuring reliable contact without tools. The LPT series from Phoenix Contact offers solutions for conductor cross-sections from 2.5 mm² to 25 mm², with horizontal and angled entries for various devices.

For multiple charging points, loop the grid feed-in from one point to the next. Preassembled cables with QPD and PRC series connectors are ideal, as their coding prevents errors, ensuring a fast and reliable setup.

Space-saving connection technology

Manufacturers handle charger wiring under controlled conditions; therefore, connection technology should be space-saving and enable quick wiring. Push-in PCB terminal blocks and connectors are ideal. Moreover, Phoenix Contact offers a wide range of connectors and PCB terminal blocks for signals and power, with various connection directions to suit different needs.

Furthermore, electric cars and AC charging points communicate via PWM signals in the charging cable, with the CP line managing the charging process and the PP contact ensuring safe charging. The maximum voltage at these contacts is 12 V, with current in the mA range. Space-saving connectors with Push-X technology are ideal for connecting these signal lines, providing direct connection and audible feedback.

Robust connectors for reliable communication

AC charging points can use LTE, WLAN, and Bluetooth for wireless communication:

• LTE: Enables remote monitoring, control, and real-time billing.
• WLAN: Allows local control via apps and integration into smart home systems.
• Bluetooth: Facilitates user authentication and short-range communication for setup and diagnostics.

These functions are often grouped on a communication PCB, which is plugged in based on the charger’s development stage. High-position Finepitch connectors are used for robust and reliable connections, essential for outdoor chargers in varying climates. AC charging points must withstand temperatures from -25°C to +55°C, with FS series connectors compensating for thermal movements.

Wired interfaces like USB-A, USB-C, and RJ45 are also available for firmware updates, diagnostics, and network connections. Phoenix Contact offers a range of connectors and cables for these needs.

Read more about E-mobility.