Design and Application of Smart EV Charging Piles

As a charging pile designer deeply involved in industry projects, I've witnessed firsthand how electric vehicles (EVs) have become a pivotal force in China's new energy landscape. Decades of advancements in electronics have laid a solid foundation for EV development. The integration of V2G, energy storage technologies, and high-performance batteries not only facilitates battery swapping services but also drives the convergence of photovoltaics, energy storage, and intelligent charging systems—a mission I'm proud to contribute to.

1. Development Status of Intelligent EV Charging Piles

Against the backdrop of rapid urbanization and escalating environmental concerns, EVs are gaining traction due to their efficiency and sustainability. As a designer, I prioritize user-centric needs: real-time access to charging station locations, precise monitoring capabilities, and intelligent management systems. These requirements underscore the development trend toward smarter, more efficient charging infrastructure.

Internationally, companies like Tesla have pioneered user-friendly mobile apps that enable seamless navigation to charging stations with price transparency. Domestically, China's grid companies have established an extensive network of over 600 charging stations and 20,000+ decentralized piles. However, a comprehensive platform integrating real-time monitoring, payment processing, and remote management remains elusive—a critical gap my team aims to address.

2. Type Design and Scenario Adaptation of Charging Piles

From a design perspective, charging piles are classified into two primary categories based on power output:

AC Charging Piles: Convert grid-supplied AC power to DC via onboard chargers. With typical power ratings of 7kW, 22kW, or 40kW, they offer slower charging speeds but greater flexibility. Ideal for residential complexes and parking lots, these piles align with overnight charging needs.
DC Charging Piles (Off-board Chargers): Deliver high-power DC directly to batteries, bypassing onboard converters. Capable of 60kW, 120kW, 200kW, or even higher, they're strategically deployed along highways, at airports, and railway stations to meet rapid charging demands for long-distance travel.

3. Charging Methods and Monitoring System Design Logic
(1) Design Considerations for Three Charging Methods

My design approach is tailored to specific use cases:

AC Charging: Best suited for small EVs and hybrids, this method relies on onboard chargers. Design focus: ensuring compatibility with diverse vehicle models and robust protection circuitry.
DC Charging: Optimized for buses and commercial fleets, it eliminates the need for onboard converters, reducing vehicle weight. Key design challenges include power management and grid integration.
Wireless Charging: While theoretically promising for dynamic charging, current limitations in efficiency and infrastructure adoption necessitate further R&D before practical implementation.

(2) Necessity of Charging Pile Monitoring Systems

Given the sensitivity of lithium-ion batteries to charging parameters, I prioritize real-time monitoring systems. These systems serve dual purposes: optimizing network distribution akin to gas stations and safeguarding battery health through precise charge/discharge control. Safety and reliability are non-negotiable design imperatives.

4. Hardware Circuit Design Practices for Charging Piles
4.1 Controller Hardware Architecture

The control system, anchored by the C44Box processor, acts as the "brain" of the charging pile. It orchestrates battery management, data acquisition, and user interfaces—supporting functions like balance inquiries, remote monitoring, and real-time display of charging metrics. A robust hardware foundation, including power circuits, NandFlash storage, and processing units, ensures system stability.

4.2 NandFlash Circuit Design Logic

Efficient data handling is critical. I configure the system to boot from ROM for rapid startup, while NandFlash stores critical data such as sensor readings and charging histories. This architecture enables quick access for user interactions and comprehensive fault diagnostics.

4.3 Power Output Control Design

Extensive testing has validated a fail-safe mechanism: detecting a 50% voltage drop in the pilot circuit for two consecutive seconds triggers load switch disconnection, halting charging immediately in case of faults. This design minimizes risks and protects both equipment and users.

5. Design Reflections and Industry Outlook

My work on AC charging piles has highlighted both progress and challenges. The complexity of system integration and software development underscores the need for deeper collaboration among standards bodies, testing institutions, and manufacturers. Future priorities include refining intelligent platforms, advancing wireless charging, and optimizing battery-charger interactions.

As designers, our mission is to evolve charging infrastructure from functional to intuitive and seamlessly integrated. Through relentless innovation and cross-sector cooperation, we can accelerate the transition to a sustainable EV ecosystem.