DC charging or Fast Charging of EVs has become a new criterion for buying an EV and choosing a public charging station as the time taken to charge an EV normally ranges from 4 to 6 hours a day.
Focusing on the same, EV Mechanica had a brief talk with Manjula Girish, Head-EV Charging and Photovoltaic Inverter Division, Delta Electronics India, Atul Gupta, Co-Founder & Director, e-Sprinto, Rohan Shravan, Founder and CEO, Tresa Motors, Jayateertha Malagi, Director – Engineering (IN), AMP.
Fast Charging Vs. Slow Charging – High Infrastructure Costs
Talking about the costs of setting up fast charging stations as compared to slow charging of EVs, there exists a major difference in the infrastructural costs for both as fast charging stations require high-level equipment.
Manjula Girish from Delta Electronics agrees with the statement that fast charging for electric vehicles (EVs) incurs higher infrastructure costs compared to slow charging is indeed accurate. Fast charging necessitates more robust and higher-capacity equipment and infrastructure to provide the higher power levels required for rapid charging, which typically includes DC chargers. While the initial investment in fast-charging infrastructure can be higher, it offers substantial advantages in terms of reducing charging time, improving user convenience, and encouraging wider EV adoption.
In line with this, Delta offers a comprehensive range of EV charging solutions that align with different specifications for electric vehicle chargers. Our AC chargers, with power outputs ranging from 3.68KW to 22 kW, are suitable for residential, workplace, and destination charging applications. These chargers are designed for both commercial and home use, providing a cost-effective solution for slower charging needs.
For fast-charging requirements, Delta’s DC chargers with power outputs ranging from 25 kW to 200 kW are well-suited for public and commercial charging services. These DC chargers optimize operating costs and are particularly advantageous in space-limited locations. By offering a variety of chargers catering to different power levels and applications, Delta aims to provide flexibility and scalability in EV charging infrastructure, helping to meet the diverse needs of the growing EV market efficiently and cost-effectively.
On the other hand, Atul Gupta from e-Sprinto expresses that fast charging for Electric Vehicles (EVs) indeed comes with a higher infrastructure cost compared to slow charging. This is primarily because fast chargers demand more advanced technology and infrastructure to deliver a higher amount of electric power to the vehicle in a shorter time frame. The hardware and electrical systems required for fast charging need to be more robust and capable of handling higher voltages and currents.
In the case of e-Sprinto, our solution offers fast charging facilities and showcases an impressively low electric consumption rate of just 1.5 units per charge. Additionally, for those who are mindful of their budget, e-Sprinto provides a cost of only 15 rupees for every 100 kilometers of travel. These features highlight our brand’s dedication to delivering not only efficient charging but also cost-effective electric mobility solutions.
Rohan from Tresa Motors believes that the future of EVs hinges on rapid and efficient charging solutions. Our commitment lies in providing cutting-edge fast-charging solutions that not only adhere to stringent specifications but also prioritize the needs of both EV operators and the broader adoption of electric vehicles.
Our state-of-the-art electric vehicle chargers are engineered with the goal of minimizing downtime for EV operators, making the charging process as swift and seamless as possible. In fact, with our technology, it takes just 15 minutes to charge your EV to 75-80 percent capacity. This remarkable speed ensures that EV owners can get back on the road quickly, with minimal disruptions to their daily routines.
By offering such rapid and efficient charging capabilities, we are not only addressing the infrastructure challenges but also contributing to the acceleration of EV adoption. At Tresa Motors, we are proud to be at the forefront of the EV revolution, making fast charging a convenient reality for all electric vehicle users, elaborates Rohan Shravan from Tresa Motors.
Jayateertha from AMP points out that fast charging for electric vehicles (EVs) indeed comes with higher infrastructure costs when compared to slow charging. The cost considerations of fast charging encompass several factors:
- Charging Speed: The first factor is how quickly you want to charge the EV. Faster charging rates require more robust and expensive equipment.
- Software and Technology: The software used for fast charging plays a crucial role. Efficient and smart charging algorithms can optimize the charging process and reduce costs over time.
- Vehicle Type: Fast chargers are primarily designed for four-wheelers and heavy-duty vehicles, which may have different requirements and infrastructure needs.
- Regulatory Compliance: Meeting regulatory standards and safety requirements adds to the cost of infrastructure. Sometimes, guidelines are not entirely clear, leading to ongoing compliance efforts.
- Location: The location of fast chargers matters. In commercial environments, where EVs are frequently used, the infrastructure cost may be justified. However, home installations, especially in apartments, might require complex permissions and setups.
- Individual vs. Shared Facilities: Unlike slow charging, which individuals can often set up at home, fast chargers are typically not suited for individual use. They are more common in shared, public locations.
Successful fast-charging solutions require advanced hardware (charging equipment) and state-of-the-art software (smart management and communication protocols) integration. This advanced software and hardware needs seamless integration, which is essential for properly functioning the charging infrastructure set up for fast charging.
Our hardware and software solutions support DC Level 3 fast charging and global charging standards such as ISO 61851, CCS (Combined Charging System), SAE J1772, ISO 15118, GB/T, CHAdeMO, and NACS.
Lack of Charging Infrastructure Disrupts Mass EV Adoption
According to Manjula, the lack of an extensive charging infrastructure has indeed been a substantial impediment to the widespread adoption of electric vehicles (EVs) in India. As the country aspires to realize its EV dream, bridging this infrastructure gap remains a formidable challenge. The Ministry of Power’s guidelines categorize EV charging infrastructure into five areas, including public charging stations and battery swapping stations. Presently, India has approximately 2,700 public charging stations and 5,500 charging connectors, a number that is expected to reach 10,000 by the end of 2025, according to Counterpoint Research.
However, considering the ambitious goal of achieving a substantial increase in EV sales by 2030, the country faces the monumental task of deploying around 20.5 lakh (2.05 million) charging stations by that time. This endeavor demands a coordinated effort from the government, private sector, and stakeholders across the EV ecosystem. It necessitates investments in grid infrastructure, standardized charging protocols, and supportive policies.
While there’s no doubt that this is a challenging undertaking, the growth trajectory is positive. India’s EV charging landscape is evolving, with government incentives, private investments, and heightened environmental awareness driving progress. As EV adoption continues to rise, especially in segments like two-wheelers, it is conceivable that India will gradually bridge the charging infrastructure gap, fostering a more conducive environment for electric mobility. Ultimately, the timeline for achieving comprehensive charging infrastructure will depend on the concerted efforts and investments in this crucial facet of the EV ecosystem.
Atul highlights that India has set a commendable target of electrifying its transportation sector by 2030. According to the Bureau of Energy Efficiency (BEE), the plan envisions the construction of 46,397 public charging stations in nine major cities by that year. However, the current reality paints a different picture, with only 5,254 charging stations spread sparsely across the country. This glaring gap between the envisioned charging infrastructure and the existing number of stations highlights the significant challenge facing EV adoption in India. While progress has been made, achieving comprehensive coverage will likely take several years. Government initiatives, subsidies, and incentives for charging infrastructure development are encouraging signs, but further investments are needed.
The shortage of charging infrastructure in India has historically hindered EV adoption. However, with the growing awareness of environmental benefits and economic opportunities, we anticipate significant progress in bridging this gap. As Tresa Motors expands its electric vehicle lineup and collaborates with partners, we aim to contribute to the development of a robust EV charging landscape in India.
Moreover, the changing energy landscape in India holds great promise for electric vehicles. Firstly, if you look at the new electricity capacity being added, it primarily comes from renewable sources, such as solar and wind energy. This shift toward green energy aligns perfectly with the eco-friendly ethos of electric vehicles and underscores the sustainability of our charging solutions.
Secondly, the Indian Government is actively establishing large-scale renewable energy plants. However, the challenge lies in efficient distribution, which is essential for powering both households and electric vehicle charging stations. We envision a future where clean energy is seamlessly transported to various regions, ensuring that EV charging infrastructure is not limited to specific areas but is accessible nationwide.
Additionally, an exciting development on the horizon is the involvement of small entrepreneurs and farmers in setting up solar plants on the plots of land that they own. Startups are already pioneering efforts to integrate these lands into the renewable energy grid, offering additional income streams for farmers. This decentralized approach to energy generation can play a pivotal role in closing the electricity gap between Tier 1 and Tier 2 cities and simultaneously create opportunities for expanding EV charging infrastructure, explains Rohan.
Jayateertha feels that the lack of charging infrastructure in India has significantly hindered the widespread adoption of electric vehicles (EVs). Pointing out the factors hindering the adoption of EVs includes,
- Diverse Driving Patterns and Distances: India’s driving patterns and distances vary significantly compared to other nations. This diversity requires a different approach to charging infrastructure to accommodate various user needs.
- Vehicle Density: India’s high population density and growing number of vehicles put additional pressure on the need for adequate charging infrastructure.
- Range Anxiety: The scarcity of charging stations leads to range anxiety among EV users, a significant deterrent to adoption.
- Climate Variability: India experiences diverse climate conditions across its regions, necessitating charging solutions that operate effectively under different environmental circumstances.
- Varied State Policies: Each Indian state has its policies for power distribution, leading to inconsistencies in the availability and reliability of power supply for charging.
- Lack of Cohesive Policy: India needs a cohesive national policy for EV charging infrastructure, which can create challenges in developing a unified charging network.
- Stability of Power Supply: Power supply stability is an issue, with load balancing being a challenge due to insufficient power distribution infrastructure.
- 2-Wheeler Charging: Charging infrastructure for two-wheelers is less problematic as many users can charge their vehicles at home or through battery-swapping solutions.
- Logistic Companies and Partnerships: Logistic companies are developing their charging infrastructure to support their EV fleets. Additionally, some companies are trying to partner with petrol stations for quicker deployment, although progress in this area could be faster.
- Challenges for 4-Wheelers and Heavy-Duty Vehicles: The gap in charging infrastructure primarily affects four-wheelers and heavy-duty vehicles, and it must be bridged after a period of time.
- Timeline for Improvement: It is estimated that it will take approximately ten years to improve the charging infrastructure gap significantly. This timeline is contingent on factors such as the growth rate of EV adoption and the willingness of charging companies to invest despite the current challenges.
Challenges in Developing Fast-Charging Solutions
Fast-charging solution providers encounter several critical challenges during the development stages of their systems. One of the primary challenges is the substantial infrastructure costs associated with installing high-power charging stations. This includes upgrading the electrical grid, installing high-capacity transformers, and implementing safety measures, all of which require significant capital investment. Compatibility and standardization issues also pose a challenge, as there is no universal standard for fast charging connectors and protocols, leading to potential interoperability problems. Managing heat generated during rapid charging, preventing battery degradation, complying with diverse regional regulations, and ensuring a seamless user experience are additional hurdles. Moreover, the environmental impact of high-power charging and the need for grid integration further complicate the development process. To overcome these challenges, fast charging solution providers must engage in continuous innovation, collaborate with regulatory bodies, and invest in research and development to create efficient and sustainable charging solutions that support the growing electric vehicle market, says Manjula.
Atul points out that as a fast-charging solution provider, we have encountered several challenges in the development stages. One of the primary hurdles has been ensuring interoperability with a diverse range of EV makes and models, each adhering to unique charging standards. This underscores the ongoing need for standardization efforts within the industry. Additionally, addressing power grid limitations has been crucial. The high-power demands of fast charging often necessitate upgrades to the local electrical infrastructure, requiring close collaboration with utility providers. The physical installation process has also posed logistical challenges, involving tasks such as identifying suitable locations, obtaining necessary permits, and establishing weather-resistant infrastructure. Furthermore, maintaining the reliability of fast chargers in the face of high usage and promptly addressing any technical issues has been imperative. Notably, effective customer education is essential, given that many users are new to fast charging, necessitating clear instructions and support for a seamless charging experience.
Whereas, Rohan comments that to truly support and facilitate the transition to electric vehicles (EVs), it’s imperative that the entire ecosystem comes together in a concerted effort. Fast charging solutions are a crucial component of this shift, and they rely on collaboration across various sectors.
Fast charging providers, in particular, face substantial challenges such as substantial initial infrastructure investments, grid upgrades, and ensuring compatibility with a diverse range of EV models. However, the success of fast charging solutions is not solely contingent on their efforts alone.
Utility companies play a pivotal role in upgrading the grid infrastructure to handle the increased demand for electricity. Governments need to provide the necessary regulatory support and incentives to encourage the adoption of EVs and the expansion of charging networks. Automakers must continue to produce a diverse array of EV models to meet consumer needs and preferences.
Furthermore, partnerships between industry stakeholders, research institutions, and technology innovators are vital for advancing fast charging technology and infrastructure. Collaboration can drive innovation and streamline the implementation of standardized charging solutions.
There are several challenges when developing a safe and reliable fast charging system. Those include compliance with various charging protocols and safety regulatory requirements based on geographies. Secondly, the charger must work with different types of cell chemistries, battery pack architectures, BMS designs, and maturity/quality of BMS algorithms. Long-term reliability and operation cycle testing are time-consuming. The designs also need to be customized for specific communication and security requirements. Lastly, ease of use for consumers is very critical.
On a macro level, there are critical issues related to grid stability and availability of sustained high power, power quality, buyer reluctance due to high initial costs, payment method integration, and localized power distribution having different rules/tariffs, highlights Jayateertha.
Fast Charging Reduces Life Expectancy of EV Batteries
Fast charging indeed exerts substantial stress on electric vehicle (EV) batteries, which can impact their overall health and longevity. The rapid infusion of current during fast charging generates heat and places mechanical stress on the battery cells. This can lead to increased wear and tear, ultimately reducing the battery’s life expectancy. While the degradation might not be immediately noticeable, over time, it can result in diminished driving range and overall battery performance. However, it’s essential to emphasize that modern EV batteries are designed to withstand this stress to a considerable extent. The large initial capacity of these batteries combined with gradual losses in capacity means that battery aging is often imperceptible to drivers. On average, EVs experience a relatively modest loss of about 2.3% of their battery capacity per year. For context, if you start with an EV with a 240 km (150 miles) range, you would likely have only lost around 27 km (17 miles) of usable range after five years.
To overcome the challenge of battery degradation due to fast charging, manufacturers are continuously working on improving battery technology, including advanced thermal management systems and more robust battery chemistries. These innovations aim to mitigate the impact of rapid charging and ensure that EV batteries maintain their performance and longevity, providing a viable solution to the challenge posed by fast charging, explains Manjula.
Atul feels that fast charging, which provides the benefit of rapid recharging for electric vehicles (EVs), can introduce certain concerns regarding the overall health of EV batteries over time. A primary issue revolves around the potential for increased battery degradation due to the swift influx of electric power, which leads to elevated heat levels within the battery cells. However, it’s important to underscore that modern EVs come equipped with advanced battery management systems (BMS) and thermal management systems, which effectively address and alleviate these concerns. In terms of a viable solution, continuous advancements in battery technology and charging infrastructure are actively addressing this challenge. Battery chemistries are evolving to enhance their resilience to fast charging, and ongoing research focuses on improving how batteries manage and dissipate heat during the charging process. Furthermore, the implementation of smarter charging algorithms and software updates is underway to optimize charging speeds based on various factors, including battery temperature and state of charge. This adaptive approach aims to find the delicate balance between providing rapid charging convenience and preserving the long-term health and longevity of EV batteries.
Confident in its design, Rohan discusses that fast charging’s impact on EV battery life is a concern, but at Tresa Motors, we have taken measures to mitigate this issue. Our battery packs, such as the Meg50, utilize innovative cooling methods and offer modularity for easy replacement. This approach helps maintain battery health, ensuring long-term performance and minimizing the impact on overall battery life.
Expressing a different point of view, Jayateertha from AMP explains that it is wrong to say that Fast Charging alone dramatically reduces the life expectancy of EV batteries unless fast charging is the only method used to charge. In a well-publicized test conducted in the US where two electric cars were tested, one was always charged with AC, and the other was charged with DC. At the end of 50,000 miles, there was only a ~4% difference between the two w.r.t SoH levels. Secondly, modern EVs have control mechanisms to adjust DC fast charging, where ~80% is fast charging, followed by ‘slow’ charging for the remaining 20%.
Battery pack degradation is highly dependent on sustained ambient conditions, thermal management of battery packs, uniformity of temperature distribution inside the battery pack, BMS algorithms, hardware design, and vehicle architecture, apart from many other factors. A battery pack charged at 45C will experience higher degradation than a pack charged at 25C, with everything else remaining the same.
Fast charging is not a replacement for everyday AC (Level-2 charging). As a rule, it is recommended to use fast charging on a need basis (e.g., long drives, emergency).
In coming years, better algorithms & OTA updates (using real-time data generated by EV battery packs), alternate chemistries, improved thermal management materials, and cooling methods will help charge at even higher currents /speeds.
Impact of Fast Charging Solutions in Electric Mobility Space
At Delta Electronics, our core focus is on pioneering innovation in the electric mobility market by providing cutting-edge fast charging solutions. We recognize the pivotal role that electric vehicles (EVs) play in transitioning to a sustainable future, and our commitment to this cause is unwavering. Our fast charging solutions are designed with a multifaceted approach that places user convenience, environmental sustainability, and technological advancement at the forefront. Our fast charging solutions significantly contribute to the electric mobility market in several key ways. Firstly, they address the critical issue of range anxiety by drastically reducing charging times, making EVs more practical and appealing for everyday use. This convenience factor is essential in accelerating the adoption of electric vehicles.
Moreover, our solutions prioritize grid integration, ensuring that fast charging stations can be seamlessly incorporated into existing electrical infrastructure. This approach not only minimizes grid stress but also enhances overall grid stability, crucial for supporting the growing EV ecosystem. Furthermore, we are committed to environmental sustainability. Our fast charging solutions are designed to be energy-efficient, reducing operational costs for charging station operators and minimizing the carbon footprint associated with EV charging. In essence, Delta Electronics’ focus is on providing comprehensive fast charging solutions that empower the electric mobility market. Through our dedication to innovation and sustainability, we contribute to the broader goals of reducing greenhouse gas emissions, conserving energy resources, and creating a cleaner and greener future for transportation, concludes Manjula.
Atul highlights that e-Sprinto primary focus is to drive the adoption of electric mobility by providing innovative and efficient fast charging solutions. We are committed to developing charging infrastructure that not only meets the needs of today’s electric vehicle users but also contributes to the long-term sustainability of the electric mobility market. Our fast charging solutions play a pivotal role by offering convenience and speed to EV users, reducing range anxiety, and promoting the widespread adoption of electric vehicles. We aim to make fast charging widely accessible, reliable, and environmentally friendly, thereby accelerating the transition to a cleaner and more sustainable future in the electric mobility sector.
Tresa Motors is dedicated to designing and manufacturing medium-to-heavy electric vehicles tailored for the Indian market. Our fast charging solutions play a pivotal role in electric mobility by enabling long-distance travel and reducing operational costs for commercial fleet owners. We take pride in our contribution to the electrification of transportation in India, emphasizing profitability for our customers and the comfort and safety of drivers, elaborates Rohan.
Summing up their contributions in the electric mobility domain, Jayateertha concludes, that AMP’s primary focus is on creating a comprehensive vehicle ecosystem for electric mobility, spanning various industries such as marine, off-highway, passenger vehicles, commercial vehicles, evTOL, drones, and logistic robots. We have a multifaceted approach to this ecosystem, with fast-charging solutions being one of the many aspects we contribute to. Here’s how our fast-charging solutions make a significant impact on the electric mobility market,
- Energy Management System: Our core focus is creating an integrated energy management system. Charging is just one component of our holistic approach.
- Platform Design: We adopt a platform-based approach encompassing hardware, software/algorithms, firmware, and analytics. This comprehensive design enhances the safety and efficiency of power management within electric vehicles.
- Safer Power Management: Our solutions aim to make power management within vehicles safer, optimizing battery utilization and extending battery life. This contributes to overall cost savings for electric vehicle owners.
- Integrated Hardware: We provide integrated hardware solutions that reduce installation and operating costs, making electric mobility more accessible and cost-effective.
- Vehicle-to-Everything (V2X): Our charging solutions are designed to eventually enable V2X connectivity, allowing electric vehicles to interact with other vehicles and infrastructure, enhancing overall mobility and sustainability.
- Charging Standards Compliance: One of the notable advantages of our solutions is that a single product can potentially comply with multiple charging standards and protocols, ensuring compatibility with a wide range of charging infrastructure.
- Security: We prioritize security for connected charging usage, offering secured fast charging to protect both the vehicle and the charging process.
- Easy Integration: Our software can be seamlessly integrated into a vehicle’s Electronic Control Unit (ECU), ensuring smooth communication and control of the charging process.
- Precise Charge Control: We provide precise control over the charging process, optimizing it for the specific needs of each vehicle and battery type.
- Automotive-Grade Reliability: Our hardware and firmware are of automotive-grade quality, ensuring reliability and durability in demanding environments.
- Safety Rating: Our solutions are ASIL (Automotive Safety Integrity Level) safety-rated, meeting stringent safety standards.
- Modular and Flexible: We offer a modular and flexible approach, allowing for quick customization to meet the unique requirements of different vehicles and applications.
- Interoperability: Our solutions are interoperable, meaning they can work with charging stations from any manufacturer. This ensures flexibility and choice for electric vehicle owners.