Guide to choosing charging cables and connectors for electric vehicles

Published : 06/29/2022 10:00:00

Electric mobility is among the most green impact markets in the public imagination, and its development has yet to reach full maturity. Although problems with the lack of raw material supply and the resulting shortage of microchips is slowing the growth of BEV and PHEV vehicle sales, the trend continues to be the focus of media and cultural attention.

As the e-vehicle market grows, so does the need for a technologically advanced charging infrastructure with a widespread presence. In fact, public charging points in Italy are about 30,000 (May 2022), while in other countries such as Germany and France the situation is better, with more than 63,000 and 55,000 charging points, respectively.

Europe also has a 19% share of electric vehicles sold in the global total, ahead of China, which has a 15% share (growing rapidly), and the United States, which closes the ranking with 4% (December 2021). The sale of electric vehicles, therefore, will see steady growth, partly as a result of the proposal accepted by the European Parliament to eliminate the production of gasoline and diesel vehicles from 2035.



Cavi e connettori di ricarica per la mobilità elettrica



What are the main charging connectors for electric mobility?



Let us therefore try to explain how electric vehicle batteries are recharged, what components are needed, and what types of charging exist. The cable that usually comes with the vehicle is in fact characterized by a connector and a plug that allow the connection between the vehicle and the charging station socket; therefore.

Currently there are four types of plugs for charging electric vehicles: two AC and two DC:

  • Type 1: is a single-phase plug found in electric vehicles from the U.S. and Asian markets and charges the car up to 7.4 kW;
  • Type 2: can be single-phase or three-phase and is the European standard for electric mobility. It is a triple-phase plug and allows charging speeds up to 43 kW at public charging stations.



Cavi e Connettori per ricarica di veicoli elettrici - Personalizzazione e customizzazioni



Then there are the chapters on home recharging, connecting directly to the home network (chargers from 3 to 22 kW) and on fast and ultra fast charging systems (up to 350 kW).

In the area of fast and ultra-fast charging of electric vehicles, two standards developed by as many associations of EV manufacturers have established themselves in the market:

  • CHAdeMO: is a two-way charging system designed in Japan and characterized by its high charging speed of up to 100 kW;
  • CCS: is an improved version of the Type 2 plug that provides two additional power contacts allowing faster charging, reaching a speed of 350 kW.



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Connettore di ricarica per veicoli elettrici



The type 2 connector: the Italian standard



In Italy the most widespread connector is the Type 2; in fact, this solution represents the European standard for AC charging of electric vehicles. It can be used within both single-phase and three-phase systems, and it is precisely because of this versatility that it has spread with great success. The Type 2 connector must provide a system for retaining the plug in the socket and has seven contacts: 5 power and 2 communication.

Power contacts:

  • L1, L2, L3: are the phase conductors, where the phase is none other than the electrical wire intended for the passage of current;
  • N: is the neutral conductor; it is a zero-potential connector, electrically connected to the center of the transformer that promotes the distribution of electric current. If the neutral of the line supplying the loads on a phase is interrupted, the current is interrupted and the voltage on them is nulled;
  • PE: is the protection conductor; it makes the connection of the grounds with the grounding system. It therefore has the function of conveying fault currents, which may occur on the grounds in case of failure of insulators or in earth electrodes placed in the ground.



Communication contacts:

  • PP: this is the proximity contact that does not provide special functionality;
  • PC: is the pilot control and the conductor through which information for communication is transmitted.



Connettore Tipo 2 - Contatti di potenza e comunicazione



Certifications required for the trade and use of cables and connectors



In addition to the CE mark, electric vehicle charging cables and connectors require some specific certifications:

  • RoHS certification: legislation 2002/95/EC was adopted by the European Community to impose restrictions on the use of hazardous substances found within electrical and electronic components. Under this directive, manufacturers are therefore required to replace chemicals deemed most hazardous with less impactful alternatives.
  • IATF 16949 certification: is a quality standard specifically for the automotive market; it is based on ISO 9001, with the addition of more detailed requirements for the automotive industry. It is a fundamental prerequisite for being able to develop projects within this market and offers guarantees regarding the company's quality management system.
  • TÜV Certification: is a set of German-originated certifying bodies involved in issuing quality certificates in the areas of safety management systems, product certification, inspection and technical support. Its deep-rooted presence in Germany and Italy, nations with great automotive backgrounds, gives it considerable importance.



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Certificazioni per la ricarica di veicoli elettrici



Digimax has a range of components useful for the realization of charging stations: power supplies, TFT LCD displays, IoT sensors, industrial motherboards, cables and connectors; everything you need for the realization of electric mobility charging stations.



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