Smart Quad EV Charger

Trent Glaze Django Demetri Calvin Pereira

Senior Design Project Proposal

Trent Glaze, Django Demetri, Calvin Pereira https://smartquadevcharger.weebly.com/
Sonoma State University Department of Engineering glazet@sonoma.edu
Advisors: Dr. Sudhir Shrestha and Bob Salter pereiraca@sonoma.edu
Client: Neil Hancock demetrid@sonoma.edu
04/26/2024
 Overview
• Problem Statement, Value Proposition, Existing and Proposed
Solution
• Marketing and Engineering Requirements
• System Overview
• Alternate Design Matrices
• Challenges and Risks
• Summary of Tests and Results
• Budget and Materials
• Schedule
• Supporting Courses
• The Journey
• Questions
• Appendix
2
 Problem Statement
Our Smart Quad EV Charger (SQEC) addresses the
concerns of property owners with parking facilities
designed for cars parked for more than 4 hours and
lack sufficient EV chargers to meet the demands of
their residents.
These property owners are trying to accommodate
more people plugging in their EVs with limited
infrastructure, resulting in frustration and constraints
due to the prohibitive costs of supplying enough EV
chargers.
The need for upgrades, especially with California
mandating EV chargers, hinders property owners
from effectively servicing more cars at a lower cost.
3
 Value Proposition

Our Smart Quad EV Charger helps individuals seeking

long-term parking solutions, like those in apartments,
workplaces, stadiums, and train stations, who aim to
conveniently charge their EVs by minimizing the scarcity
of charging points and increasing the charge point
capacity fourfold, distinguishing itself from traditional
single/dual-port chargers.

4
 Standards
-IEC 61851: A wide spreading document that specifies EV conductive
charging systems. This includes chargers, cars, power, communication, and
protection.

-SAE J1772: A standardization of charging equipment, derived from IEC

61851. Includes only chargers.

-CalGreens: Government standards forcing adoption of EV. For example, a

percentage of parking spaces must have chargers.
5
 Existing Solutions

REV+ Charger Enphase Charger Electrify America Charger

Pros Cons Pros Cons Pros Cons

- 50 A max - Dual Port - 40 A max - Dual Port - 40 A Max - Single port
- Smartphone - No on-board - Smartphone - Very Expensive - Remote - No on-board
connection display connection - No on-board Access display
- Split current display control
- Split current

6
 Proposed Solution
ESP32-S3 *Rated for:
SQEC 250 VAC
Main Board
802.11b/g/n EV1
50 A

Sub Panel
EV2

GUI

EV3

EVSE
NFC Card Current EV4
NFC (Electric Vehicle
Reader Supply Equipment) Transformers
User
7
 Proof of Concept
Relay

GUI

GUI + Push Buttons

NFC Reader
SQEC Main Board 8
Schematic

9
 Marketing Requirements
MR-1. Shall be able to plug in four SAE (Society Automotive Engineers) standard EVs at
once.
MR-2. Ability to service multiple EVs over a 2 hour period. (Time vs current sharing detailed
in report)
MR-3. Shall have a simple user interface that informs the user of charger status
MR-4. Shall prompt user in the event of EVSE failure.
MR-5. Shall be able to connect to a wireless internet network.
MR-6. Shall identify the user information for billing purposes.

10
 Engineering Requirements
ER-1. Must be able to generate the control pilot signal with tolerance of ± 600 mV and ± 5 Hz as well as
control the duty cycle of the control pilot signal, as dictated by IEC 61851 6.3.1.3. (MR 1,2)
ER-2. Must switch current in accordance with control pilot’s five voltages, (12 V, 9 V, 6 V, 3 V, 0 V), as
dictated by IEC 61851 A.4.6(MR 1,2)
ER-3. Must be capable of switching current nominally at 250 VAC. (MR 2)
ER-4. Must be capable of switching current nominally at 40 A. (MR 2)
ER-5. Must have an interface that displays the number of active charge points. (MR 3)
ER-6. Must be able to visually signal a non-functional state that is visible within 5 ft, line of sight. (MR 4)
ER-7. Must successfully send packets 999 out of 1000 attempts. (MR 5)
ER-8. Must have a payment device that successfully reads 99 of 100 attempts. (MR 6)

Note: IEC stands for International Electrotechnical Commission, which creates industry standards
11
System Block

12
Hardware Block

13
Software Design

14
 Alternate Design Matrices (1)

Microcontroller Weight ATMega128RFR2 WFI32E01PE ESP32

Price 0.3 0.2 0.5
[$] 0.6 [7.61] [13.11] [5.85]
Support 0.2 0.1 0.7
[F/P/V] 0.4 [5/587/20] [1/273/0] [7/31878/20]

Score 0.3 0.2 0.6

Note: The ESP32 was chosen because it had sufficient PWM pins, integrated Wi-Fi,
adaptable serial communication pins (UART, SPI, and I2C), and had the necessary number
of pins. The alternate design matrix has no ability to convey this information.
15
 Alternate Design Matrices (2)

CFAF800480E1-05
Displays Weight 0SR ILI9341 RPi Display #16381
Price 0.3 0.5 0.2
[$] 0.7 [31.27] [25.85] [50.39]
Size 0.4 0.2 0.4
[inches] 0.3 [5] [4.3] [5]

Score 0.3 0.4 0.3

Note: The ILI9341 was chosen because it had the 9341 chip which, not only had lots of
online references, but also a documented library. The alternate design matrix has no
ability to convey this information.
16
 Challenges

Challenges:
● Finding parts for decent prices and delivery times
- Compared multiple suppliers and planned ahead so delivery
times do not violate deadlines
● Emulating the interfacing of an EV to an EVSE
- Simulated the circuits with LTspice
● Meeting the IEC standards
- Researched what affected the tolerances and consulted
component datasheets

17
 Risks
Risk Score Mitigation Contingency

Switching
10/25 -Buy contactor with high electrical Swap faulty contactor with a
contactors stuck
switch cycles without failure replacement
closed
-Peer reviewing software
Flashing new code onto the
Software Failures 8/25 -Stress testing
microcontroller.
-Test with low power initially

Comparator
- Power cycle the circuit and reset
Specification 5/25 Replace the comparator
the clock
Deviation

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 Key Tests
ER/MR to
Test Number Objective Status Notes
address
Satisfying IEC
61851 Table 1kHz Square wave signal, ±5Hz
FT.1 6.3.1.3 for Control ER.1 PASS accuracy
Pilot Freq.
Accuracy
Satisfying IEC
61851 Table
±12V Square wave signal,
FT.2 6.3.1.3 for Control ER.1 PASS
±600mV
Pilot Voltage
Accuracy

Demonstrate the
The GUI should display: kWh
ST.3 GUI can Provide MR.3
PASS used, elapsed time, and plug
User Relevant
status for each plug
Data
19
 Test Results – 20

Frequency Tolerance (FT 1)

Objective: Prove the ESP32 and MC IC

is able to produce a PWM signal
within ± 5 Hz as dictated in ER1.

Setup:
Expected Outcome: Since the
ESP32 has a frequency stability of
20 ± 5 ppm, the PWM should be
1000 Hz ± 0.00004 Hz.
 Test Results – 21

Frequency Tolerance (FT 1) Cont’d

Results:
Procedure:
Measured Average Measured Deviation
1. Power the ESP32 and confirm PWM Frequency (Hz) (Hz)
generation (Test Point A) is occurring
1000.0031 ± 0.0055
via frequency counter (53132A).
2. Connect frequency counter probes
to Test Point B.
3. Record ten values from the
frequency counter.

Conclusion:
Pass
 Test Results – 22

Frequency Tolerance (FT 1) Calculations

 Test Results – 23
23

Voltage Tolerance (FT 2)

Objective: Prove the ESP32 is able to

produce
a PWM signal with a voltage with a Setup:
tolerance
of ± 600 mV, as dictated in ER1.

Expected Outcome: Since the

datasheet gives an output
impedance of 2 Ω at 1kHz, the
voltage should be 11.959808 V
and -11.959808 V.
 Test Results – 24
24

Voltage Tolerance (FT 2) Cont’d

Procedure: Results:
1. Set the ESP32 to produce a 100% duty Positive Voltage (V) Negative Voltage (V)
cycle PWM signal and confirm (Test 11.844461 ± 0.000006 -11.817122 ± 0.000006
Point A) is occurring via DMM (3458A).
2. Connect multimeter probes to Test
Point B.
3. Record ten voltage values from the
multimeter
4. Repeat Steps 1 through 3 with 0%
duty cycle

Conclusion: Pass
 Test Results – 25
25

Voltage Tolerance (FT 2) Calculations

Input Impedance of DMM:

 Test Results – 26

GUI Interaction (ST 3)

Objective: Prove the display, EVSE Setup:
Interface Circuit, NFC Reader, and
Current Transformer Circuit can
display plug status, elapsed time,
and kWh for each plug
Initial Conditions:
1. ESP32-S3-WROOM1
producing a 3.3 V PWM signal
2. NFC on standby
3. No EV switches triggered
4. Display on welcome screen
5. No GUI buttons pressed
 Test Results – 27

GUI Interaction (ST 3) Cont’d

Pilot
State EV Resistance (Ω) GUI Screen Description
(V)
Welcome
State A +12 N/A Not Connected
Screen Control Pilot Signal
Tap Card EV Connected
State B +9 2.74k
Screen (Ready)
State C +6 882 Plug Status EV Charge
EV Charge
State D +3 246 Plug Status Vent.
Required
State E 0 N/A N/A Error
State F -12 N/A N/A Unknown/Error

Control Pilot State Table

 Test Results – 28

GUI Interaction (ST 3) Cont’d

Inputs:
Screen 1: Welcome Screen “Presence” EV Resistor Not connected

“Charge” EV Resistors Not connected

RFID Card/Tag Not read

GUI Button Not pressed

Expected Outcome:
Welcome Screen Yes

Ask for RFID No

Card/Tag

Display Plug Status No

 Test Results – 29

GUI Interaction (ST 3) Cont’d

Inputs:
Screen 2: Tap Card Screen “Presence” EV Resistor Connected

“Charge” EV Resistors Not connected

RFID Card/Tag In progress

GUI Button Not pressed

Expected Outcome:
Welcome Screen No

Ask for RFID Yes

Card/Tag

Display Plug Status No

 Test Results – 30

GUI Interaction (ST 3) Cont’d

Inputs:
Screen 3: Plug Status Screen “Presence” EV Resistor Connected

“Charge” EV Resistors Connected

RFID Tag Read

GUI Button Pressed

Expected Outcome:
Welcome Screen No

Ask for RFID Tag No

Display Plug Status Yes

 Test Results – 31

GUI Interaction (ST 3) Cont’d

Observations: The circuit works as expected. GUI is slower than anticipated

and that decreases the usability.

Conclusion: Pass
 32

Estimated Budget
Item Part No. Purpose Manufacturer Supplier Price Qty Ext. Price
ESP32S3-DevkitC-Wroom -EV-EVSE interfacing
MCU Expressif Digikey $26.98 1 $26.98
1 -Operate relays
LCD ILI9341 -Display Gui Hosyond Amazon $15.99 1 $15.99
NFC RC522 -Capture user ID Qunqi Amazon $2.55 1 $2.55
Op-Amp MC34074ADR2G -Amplifies the PWM signal from ESP onsemi Digikey $0.94 1 $0.94
Relay 450BXX50-12 -Allow or stop current to EV Struthers-Dunn Digikey $39.99 4 $159.96

Current Transformer CT-1050 -Measure the amount of power taken by EV Amgis, LLC Digikey $9.66 4 $38.64
10KW Resistor TE1000B10RJ -For testing at 208V TE Connectivity Digikey $73.73 1 $73.73
Various Resistors Various -EV, EVSE, Relay, LED, CT, cuirts YAGEO Digikey $10.00 1 $10.00
LEDs Green, Red -Indicates accept, error Broadcom Digikey $0.79 2 $1.58
Transistor MMBT2222A MMBT2222A EVVO Digikey $0.03 6 $0.18
Diode S1A -Relay Driver surge protection SMC Solutions Digikey $0.04 4 $0.16
Various Capacitors Various -EV, EVSE, CT circuit Samsung Digikey $0.10 10 $1.00
SQEC PCB V3 - Main board of the SQEC JLCPCB JLCPCB $2.00 1 $2.00

Electrical Box NA - Housing for the EVSE Schneider Home Depot $64.99 1 $64.99

Total $398.70
Schedule

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 Supporting Courses

• Electronics I (EE 230)

• Understanding op-amp and transistor circuit design (rectifiers and
comparators)

• Microprocessors and System Design (EE 310)

• Learned to interface microcontrollers with peripherals

• Microelectronic Circuits (EE 334)

• Understanding transistor and amplifier circuit design

34
 35

The Journey: Part 1

Control
Pilot
Circuit
Control Pilot Final
Circuit V1

ADC Rectifier &

Step down

Voltage
Follower
 36

The Journey: Part 1 (Calculations)

Thevenin Expected ADC
Equivalent Values
 37

The Journey: Part 2

Output of V2

V1

Less Hardware, More Software:

-Nyquist Sampling Theorem
-Oversampling
V2 -0dB Attenuator
-Averaging
 38

The Journey: Part 2 (Calculations)

Burden Resistor vs Percent Error: Linearity of
ADC with
Attenuator
Disabled:

Diode Characteristics:

Burden Resistor Calculation:

Turns Ratio is 1:1000
 Future Work
● Design PCB with integrated ESP32-S3-WROOM1 rather than a Dev-kit.

● Test key components for deviation in various temperatures .

● Formulate new charging algorithms. The current algorithm has a stranded

power issue.

● Implement a credit card reader in place of the NFC reader.

● Implement a ground-fault protection circuit.

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 Questions

Questions/Comments

40
 Appendix i:
Demo Video

https://drive.google.com/file/d/13YPWnPpfD-qJsv1OFiJ2CFQxlMKUPZur/view?usp=sharing 41
 Appendix ii:
ADC Voltage

EV Voltage ESP32 Voltage

12V 900 - 810 mV

9V 800 - 690 mV

6V 620 - 550 mV

3V 520 - 490 mV

0V 100 - 200 mV

42
 43
Appendix iii:
Time Splitting (30min) vs Current Splitting (30min)
Ø Recharg Max
Ø Max Battery SoC @ Consum e time power @ Recharge
Battery SoC @ Consump Recharge power @ Recharge Make/M Capacit Arrival ption (minutes charge d Range
Make/M Capacity Arrival tion time charge d Range odel y (kWh) (%) (Wh/mi) ) (kW) (mi)
odel (kWh) (%) (Wh/mi) (minutes) (kW) (mi) Chevrol
Chevrole et Volt
t Volt EV 54 40% 254 30 2.4 6 EV 54 40% 254 30 9.6 19
Nissan Nissan
Leaf 3.0 62 40% 251 30 2.4 5 Leaf 3.0 62 40% 251 30 9.6 19
Hyundai
Hyundai
Ioniq 5 73 40% 283 30 9.6 18
Ioniq 5 73 40% 283 30 2.4 6
Tesla
Tesla
Model 3
Model 3
AWD 82 40% 219 30 9.6 23
AWD 82 40% 219 30 2.4 8
Ford
Ford Mach-E
Mach-E Premiu
Premium 91 40% 301 30 2.4 6 m 91 40% 301 30 9.6 18
Audi Q4 Audi Q4
E-Tron 106 40% 283 30 2.4 5 E-Tron 106 40% 283 30 9.6 18
Average Average
Recharge Recharg 19.16666
d Range 6 ed Range 667
 Appendix iv:44
Time Splitting (1 hr) vs Current Splitting (4 hr)
Ø Recharg Max
Ø Max Battery SoC @ Consum e time power @ Recharg
Battery SoC @ Consump Recharge power @ Recharge Make/M Capacit Arrival ption (minutes charge ed Range
Make/M Capacity Arrival tion time charge d Range odel y (kWh) (%) (Wh/mi) ) (kW) (mi)
odel (kWh) (%) (Wh/mi) (minutes) (kW) (mi) Chevrol
Chevrole et Volt
t Volt EV 54 40% 254 60 9.6 38 EV 54 40% 254 240 2.4 38
Nissan Nissan
Leaf 3.0 62 40% 251 60 9.6 37 Leaf 3.0 62 40% 251 240 2.4 37
Hyundai Hyundai
Ioniq 5 73 40% 283 60 9.6 35 Ioniq 5 73 40% 283 240 2.4 35
Tesla Tesla
Model 3 Model 3
AWD 82 40% 219 60 9.6 42 AWD 82 40% 219 240 2.4 42
Ford
Ford Mach-E
Mach-E Premiu
Premium 91 40% 301 60 9.6 33 m 91 40% 301 240 2.4 33
Audi Q4 Audi Q4
E-Tron 106 40% 283 60 9.6 34 E-Tron 106 40% 283 240 2.4 34
Average
Average Recharg
Recharge ed
d Range 36.5 Range 36.5
 Appendix v – 45

EVSE-EV Interfacing (ST 2)

Objective: Demonstrate the
ESP32 can operate four relays
in accordance with the
modified CP signals as
dictated in ER2.

Setup:
 Appendix vi –
EVSE-EV Interfacing (ST 2) Cont’d

Results: Conclusion:
Control Pilot Expected
The ESP32 is capable of
Pass or Fail
Voltage Outcome managing the four relays in
12 V (dc) Relay - open Pass
accordance with the control pilot.
Struthers-Dunn
450BXX50-12
Relay - open
9 V ± 0.6 Pass

Relay - closed
6 V ± 0.6 Pass
Fan LED - off
Relay - closed
3 V ± 0.6 Pass
Fan LED - on
Relay - open
0 V ± 0.6 Pass
Warning LED - on

46
 Temperature Deviation
Appendix vii
MC34074ADR2G Op-Amp Temp. Characteristics

47
 Temperature Deviation
Appendix viii
ESP32-S3-WROOM1 Temp. Characteristics:

48
 NFC
Appendix ix

Source - https://driveelectric.gov/files/payment-system-best-practices.pdf 49