SOLAR POWERED CHARGING

STATION FOR ELECTRIC VEHICLES

ENGM 690 CAPSTONE PROJECT
AAMIR SIKANDER

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 CHRISTIAN BROTHER UNIVERSITY
CAPSTONE PROJECT
MASTER OF SCIENCE IN ENGINEERING MANAGEMENT
MECHANICAL ENGINEERING
SOLAR POWERED CHARGING STATION FOR ELECTRIC VEHICLES
PROFESSOR Dr. SANJEEV BHARANI

DATE OF SUBMISSION

Aamir Sikander
alnu@cbu.edu

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 CHRISTIAN BROTHER UNIVERSITY
GRADUATE SCHOOL
April 5, 2021
I HEREBY RECOMMEND THAT THE REPORT PREPARED UNDER MY
SUPERVISION BY SANJEEV BHARANI ENTITLED Solar Powered Charging
Station for Electric Vehicles BE ACCEPTED IN PARTIAL FULFILLMENT OF
THE REQUIREMENTS FOR THE DEGREE OF Master of Science in
Engineering Management.

Dr. SANJEEV BHARANI

PROFESSOR

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CONTENTS

Abstract…………………………………………………………………………………4
Introduction………………………………………………………………………….5
Charging level for electric vehicles…………………………………………6
Charging stations……………………………………………………………………8
Rechargeable battery…………………………………………………………….9
Background of electric vehicles……………………………………………..10
Advantages……………………………………………………………………………13
Disadvantages…………………………………………………………………….…14
Parts description……………………………………………………………………15
Cost of major products……………………………………………………………18
SWOT………………………………………………………………………………………18
Methodology……………………………………………………………………………19
Discussions ……………………..………………………………………………………20
References……………………………………………………………………………….21

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Abstract
Electric vehicles (EVs) are becoming increasingly popular in the United States of
America and concern over the effects of greenhouse gases. EVs attract buyers
with benefits including energy efficiency and environmentally friendly. The main
factor in usage of electric vehicle is the charging and charging time required for
batteries used in EV. As EV usage grows, more public spaces are installing EV
charging stations. This paper proposed the design of a level 2 charging system of
EV charging station, the paper also includes the brief description on EV charging
stations, background of EV, as well as a brief description of Photovoltaic (PV)
system. Because this study took place at a private property, the results presented
here can be used as a reference for EV charging station usage in other towns in
the USA, that do not have EV charging stations but are planning to develop EV
infrastructure.

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1 Introduction
Fossil fuels are the dominate energy source for both the electricity generation and
transportation industry. However, in recent years, the climate change has raised
global awareness about the negative impacts of using fossil fuel. Governments
and industries are moving toward the use of clean energy sources and reducing
environment pollution. In this case, it is most likely involved an extensive use of
Electric Vehicle (EV) for transportation, electrification and adopting renewable
energy sources for electricity generation. As a cleaner method of transportation
with less carbon emission and energy consumption, electric vehicle is regarded as
a feasible option for replacing petroleum-fueled vehicles. However, lack of
sufficient charging infrastructure is a critical barrier to successful development of
EVs at this large scale. Therefore, there is an increasing need today to build a
properly planned infrastructure for EV charging and develop novel planning
methods of active distribution network and charging stations. Building the system
of renewable energy source for charging electric vehicle with individual
requirements which will have a capacity of 6x 100 ah 12v of battery [CITATION Bat \l
1033 ] to charge any electric vehicle with the required output.

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2 Charging levels for electric vehicles

In 1991, the Infrastructure Working Council (IWC) was formed by the Electric
Power Research Institute (EPRI) to establish consensus on several aspects of EV
charging. Level 1, Level 2, and DCFC charging levels were defined by the IWC,
along with the corresponding functionality requirements and safety systems. EPRI
published a document in 1994 that describes the consensus items of the IWC.

Level 1 – 120 VAC

The Level 1 method uses a standard 120 VAC branch circuit, which is the lowest
common voltage level found in both residential and commercial buildings. Typical
voltage ratings can be from 110 – 120 VAC. Typical amp ratings for these
receptacles are 15 or 20 amps.

Figure 1 Level 1 Charging diagram

Level 2 – 240 VAC

Level 2 is typically described as the “primary” and “preferred” method for the
EVSE for both private and publicly available facilities. Level 2 specifies a single-
phase branch circuit with typical voltage ratings from 220 – 240 VAC. The J1772-
approved connector allows for current as high as 80 amps AC (100 amp rated
circuit). However, current levels that high are rare; a more typical rating would be
40 amps AC, which allows a maximum current of 32 amps. This provides
approximately 7.7 kW with a 240 VAC circuit.

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 Figure 2 Level 2 charging

Note: For Level 1 and 2, the conversion of utility AC power to the DC power
required for battery charging occurs in the vehicle’s on-board charger. In the
DCFC, the conversion from AC to DC power typically occurs off-board, so DC
power is delivered directly to the vehicle.

DC Fast Charging (DCFC)

The DCFC is designed for commercial and public applications and is intended to
perform in a manner like a commercial gasoline service station in that recharge is
rapid. Typically, the DCFC would provide a 50% recharge in 10 to 15 minutes. The
DCFC uses an off-board charger to provide the AC to DC conversion. The vehicle’s
on-board battery management system controls the off-board charger to deliver
DC directly to the battery.
To reduce the driving range anxiety and hence to support a stronger increase of
the penetration of EVs worldwide there is the need of a charging system which
can replace the current existing oil station. A fast-charging station (FCS) can allow
the charging of an EV at 80% within a half of which all dc–dc converters are
connected. The power interface between the dc bus and the integrated storage or
the EV battery is performed by a LLC resonant converter.

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Figure 3 Levels of charging for electric vehicles

3 Charging station

Range anxiety is one of the reasons why EVs cannot be used without widely
spread charging stations network. EVs have lesser maximum range on one charge
than typical ICE vehicles, and they should spend considerable time to recharge.
However, EVs can be charged at home at night – option not available for ICE
vehicles. More than 70% of all daily drives in Europe and North America are less
than 60 km per day.

As an example of home charging, Nissan Leaf and Tesla should be considered –

Leaf has a 3.3 kW charger, while Tesla can accept 16.8 kW using its own High
Power Wall Connector. Home charging is still slow compared to an average
petrol/diesel pump, which has effective power delivery rate of 5000 kW.
Of course, there is a more rapid way to charge EVs – Fast Charging. For a long-
distance travel, there are Fast Charging stations with high-speed charging
capability using industrial three-phase outlets. They can charge most EVs to 80%
in 30 minutes. It still requires more time compared to gas refill, but in practice, it

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works well – after few hours of driving, passengers can make 30 minutes stop for
eating/drinking and resting, giving car enough time to be charged.

4 Rechargeable battery
The battery is the main energy storage in the electric vehicle. The battery in-fact
governs the success of the electric vehicle. Recently there are massive works
being reported in battery development. The battery such as Li-ion is now being
used by new generation of electric vehicle. The danger of the instability of the
battery has been studied by many reported. It seems that the LiFePO4 type is
preferable because of its chemically stable and inherently safe. Other Li-ion such
as LiCoO2,LiMn2O4 and Li(Ni1/3Mn1/3Co1/3)O2 may has the thermal and
overcharge concern. For low-cost solution, the lead-acid battery is still dominant
part of the market. The battery has found applications in electric wheelchair, Golf-
cart, micro-car and neighborhood town air. All the research is looking towards the
fast charging for batteries.

The basic scheme of the rechargeable EV is generally the following:

the battery connected to the electric motor through the power wiring and control
system. Electric motor transfers the torque to the main gear using the universal
shaft. Sometimes electric motor can be installed directly into the wheel.

-Car characteristics mostly depend on battery type – total range is directly

proportional to the ratio of the battery weight to the total car weight.
-Batteries are mostly located on the bottom of the car, in easy access places – for
faster maintenance or battery change.

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5 Background of electric vehicles

Date Timeline of electric vehicle milestones

World's first electric tram line operated in Sestroretsk near

1875
Saint Petersburg, Russia, invented and tested by Fyodor Pirotsky

World's first commercially successful electric tram, the Gross-Lichterfelde tramway

1881 in Lichterfelde near Berlin in Germany built by Werner von Siemens
who contacted Pirotsky. It initially drew current from the rails, with overhead wire being installed in 1883.

The trolleybus dates back to 29 April 1882, when Dr. Ernst Werner Siemens

1882
demonstrated his "Elektromote" in a Berlin suburb. This experiment continued until 13 June 1882

Mödling and Hinterbrühl Tram, Vienna, Austria, first electric tram

1883
powered by overhead wire.

Thomas Parker built a practical production electric car in Wolverhampton using his own

1884
specially designed high-capacity rechargeable batteries.

Dec 1996 Launch of the limited production General Motors EV1

First Tesla Roadster delivered, becoming the first highway

Feb 2008
legal electric car to use lithium-ion battery

Jul 2009 Launch of the Mitsubishi i-MiEV, the first modern highway legal series production electric car

2011 The Nissan Leaf passed the Mitsubishi i MiEV as the world's all-time best selling all-electric car

Jun 2012 Launch of the Tesla Model S

Sep 2015 Cumulative global plug-in sales passed 1 million units.

Nov 2016 Global all-electric car/van sales passed 1 million.

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 Cumulative global plug-in sales passed 2 million units

Dec 2016

5% of passenger cars on Norwegian roads are plug-ins

Jul 2017 Launch of the Tesla Model 3

First half
1 millionth plug-in electric car sold in Europe
2018

1 millionth plug-in electric car sold in the U.S.

Sep 2018
2 millionth new energy vehicle sold in China
(includes heavy-duty commercial vehicles)

Annual global sales passed the 2-million-unit mark

Dec 2018

Tesla Model 3 becomes first plug-in to exceed 100,000 sales in a single year

Dec 2019 One out of two new passenger car registered in Norway in 2019 was a plug-in electric car

Early
The Tesla Model 3 surpassed the Nissan Leaf as the world's best selling plug-in electric car in history
2020

The Tesla Model 3 is the first electric car to sell more than 500,000 units since inception.

Mar 2020

Tesla, Inc. becomes the first auto manufacturer to produce 1 million electric cars

Dec 2020 Nissan Leaf global sales reached 500,000 units.

Cumulative global plug-in sales passed the 10 million unit milestone 

The Norwegian plug-in car segment achieved a record annual market share of 74.7% of new car sales.

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 Over 15% of all cars on Norwegian roads are plug-in electric.

Figure 4 Annual sales of EVs (2011-2020)

Evolution of annual sales of plug-in electric passenger cars in the world's top
markets (countries/regions) between 2011 and 2020

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6 Advantages

There are many advantages of solar energy to consider when you are installing
solar panels, such as:

1. Energy independence
The sun is an infinite source of energy, unlike coal and natural gas, and
solar panels can be installed practically anywhere. Using solar panels allows
you to reduce dependence on foreign oil and fossil fuels, leading to a more
stable and predictable energy bill, especially during times when the
demand for energy is high.
2. Reduce your carbon footprint
Solar energy can generate power without giving off any dangerous
emissions. While there is some carbon footprint from producing and
distributing solar panel infrastructure, the energy produced from solar
panels is clean, free of pollutants and emits no gases. The average
American home produces 14,920 pounds of carbon dioxide each year.
3. Financial support from the government
Federal and state tax benefits are available when you install solar panels in
your home or business. Taxpayers could potentially claim 30 percent of
installation costs, with benefits that vary by state. The solar energy industry
also creates jobs for solar panel manufacturers and solar installers, which in
turn helps the economy.
4. Requires maintenance and has longevity
Most systems last for 20 or more years. During that time, solar panels and
equipment require little maintenance. The company you choose can help
you understand what is exactly required for maintenance. Plus, solar
energy technology is always improving, so the same size solar panels from
last year are even better today.
5. Reduced electricity bills
Using solar energy instead of traditional energy sources can result in
financial savings. Over a 20-year period, you could save anywhere from
$10,000 to $30,000, depending on your state, home size and electricity
usage. Unlike paying utility bills, paying off a solar panel system gets a

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 return on investment. Solar energy can also be sold back to the grid, so you
have the potential to earn while you save.

7 Disadvantages

As with most things where there are advantages, there are also disadvantages to
consider when thinking about installing a solar energy system. Some
disadvantages associated with solar energy systems include:

1. Inability to take it with you when you move

Practically speaking, once a solar energy system is installed on a home or
business, it is nearly impossible to transport. Theoretically, it is possible to
transfer PV solar panels if you move into a new home, but it is never
advised. The system would have to be dismantled from your roof and
retrofitted to your new property, which would likely cause extensive
damage to both your panels and your roof. Solar panels do not damage
your roof when installed properly.
2. High initial cost
The initial cost of purchasing a solar system is high, while a reduced electric
bill is an advantage, there are initial costs for the equipment, panels and
installation that could be more than $20,000. Also, if you have devices that
run on DC currents, those will be more expensive to power directly.
3. Weather dependence
The most important item with solar panels is the sun. If you live in an area
prone to cloudy days or are simply having some storms and darker days for
an extended period, this will negatively impact how the system runs,
although solar energy can still be collected during cloudy and rainy days,
the efficiency of the solar system drops. Your system will likely be less
productive in winter months than summer months.
4. Limited storage space
As the solar energy industry continues to grow and offer more nation-wide
services, most solar energy companies service a particular geographic
region or even just one state. So, if you live in an area outside of a solar
energy company’s coverage area, you could have difficulty even finding
solar options near you. Additionally, if you live in a rural area or just far

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 away from your solar provider, you could have problems reaching customer
services representatives when you need to.
5. Inconvenience in inner cities and other areas with limited space
A solar system requires a decent size of space to install the equipment and
have everything run smoothly, and so solar panels might be inconvenient in
inner cities and other areas with limited space. About 100 square feet of
roof space is required for every 1 kW of conventional solar panels. If you
have limited space or a small roof, you might not have the space for all the
solar panels needed to power your entire house.

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8 Parts description

Figure 5 Blueprint of solar kit

Solar panel

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Solar panel is also called as photo-voltaic (PV) module, A PV module is an
assembly of photo-voltaic cells mounted in a framework for installation. Photo-
voltaic cells use sunlight as a source of energy and generate direct
current electricity. A collection of PV modules is called a PV Panel, and a system of
Panels is an Array.
Inverter
Your battery bank stores power at 12 volts. If you have something, say, a coffee
maker or an instant pot… you will need 110 volts or normal household
plug. The inverter takes the 12v power stored in the batteries and converts it into
110v power so you can power those household appliances.
-4000-Watt Pure sine wave Inverter 48V
Charge Controller
The Charge Controller takes the solar power from the solar panels and then
converts it into a form of more organize and useful power. The power is coming
from the solar panels at varying voltages. Anywhere from 16 volts to, potentially
in the hundreds of volts depending on the setup.  The charge controller regulates
that voltage down to the 12-15 volt ballpark to properly charge, said battery bank.
-100 Amp Maximum power point tracker (Mppt) Solar Charge Controller
Batteries
Batteries are simply storage tanks for power. They store the power that the solar
panels and charge controller have made until it’s ready to be used to run
computers, charge phones…or whatever. A Battle Born Lithium Battery is about
12 ¾ x 7 x 9 inches.
-100 Ah 12V lithium battery
Battery Isolator
This is the device that lets you change your solar battery bank with the engine
alternator. It lets power pass when the engine is running and it closes when its
engine is off so you don’t drain your starting battery as you use your
solar batteries.
Busbar

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The Busbar is an extension of your battery terminals. When we’ve got a dozen
different wires and components that need to be connected to
the battery ‘directly’, the top of the battery terminal can turn into a giant bird
nest of wires in a hurry. These just give you a little more room to work with your
wiring and make it easier to see exactly what you have got going on and what
wires are going to where.
Battery Monitor
The battery monitor tells you the status of your batteries. Like, their capacity,
voltage, and how much power are actively being generated or lost. The monitor is
able to tell us this information by the information provided by the shunt.
Shunt
The shunt is physically responsible for ‘counting’ the amps that are either coming
or going in either direction and reporting that to the battery monitor. If
the Battery Monitor is the brain, the Shunt is the body. The Shunt sits in line of
the negative battery terminal and the bus bar. All loads should be on side of
the shunt that’s away from the battery.
Fuse block
This fuse block is the easiest way to make fused connections to those low
amperage devices and keep everything safe, tidy and organized.  This is how you
will run all of your wires to your accessories like lights, fans, 12v outlets, 12v
refrigerator, USB ports, etc.
Fuses
Fuses are what protect your wires in case of an over-current situation which is a
malfunction. If there are too many amps flowing through too small of a wire (or if
something is malfunctioning), the wire can melt and possibly start a fire. The fuse
is designed to ‘blow’ or ‘trip’ at a current lower than that point which will cut the
flow of power, effectively shutting off the hazard.
Wires

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Wires transport power from one component to the next. This comes in various
sizes. “Small wire” for use on lights and fans would be somewhere in the 12–18-
gauge.
9 Cost of major products
Charge controller: Victron Energy Blue Solar MPPT 100V 20 amp 48-Volt Solar
Charge Controller $170
Inverter: SUNGOLDPOWER 4000W Max 12000W Input 240VAC Split Phase 120V /
240V Output $895
GIANDEL 4000W Heavy Duty Pure Sine Wave Power Inverter DC12V to AC120V
$580
Solar panels: Renogy 175 Watts 12 Volts Monocrystalline Solar $300
SUNGOLDPOWER 100-Watt 12V Monocrystalline Solar Panel $230
10 SWOT Analysis
Strengths
-Environmental friendly
-Easy to install and locate
-Variety of multiple output connections
-Can generate power for different utility product
-Home charging -safe and reliable
Weakness
- Efficiency depends on seasonal variability
- Numerous suppliers for different components
- High cost of installation
- Longer charging time
- Charges only compact electric vehicles

Opportunities
- Growing popularity of solar energy
- Good benefits and tax breaks from government
- Electricity establishing a new source of powering vehicles
- Increasing concern about global warming
Threats

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 - Competitors in the market
- Similar ideas or features in market causing conflict
- Transforming towards sustainable energy
- Other renewable source of energy and hybrid energy technology
10 Methodology

11 Discussion
This paper is written to provide an overview on the technology, the operation and
the status of the available solar charging methods, the issue of solar–
grid integration with the charger will be more demanding. Furthermore, the safe
charging procedures using battery management system need to be maintained to
ensure long life of the EV batteries.

12 Conclusion
13 References

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