110 Chapter 9 Another connector issue that should be properly evaluated is the module-to-module and cell-to-cell connections. Some connector manufacturers have developed some interesting connector options that can improve ease of installation and serviceability. One such example is Amphenol who have developed a unique “Radsok” type connector that is designed for easy installation and disassembly. One of the current challenges of them is that they are still a bit more expensive than more traditional connector options. Two final thoughts on wiring and connectors: It is especially important to ensure that the connectors that are chosen have a positive locking mechanism built into them.
This is very important in applications that are transportation based but should be considered in all battery systems. By integrating interlocking connectors you are ensuring that the connections do not disengage or separate over time. You may also notice that much of the “standard” high-voltage wiring and cables has a specific orange coloring; this is because SAE standard J1673 defines the requirement for identifying these in automotive applications.
Charging While we will not go into great detail on battery charging in this book as it is considered to be on the “other” side of the battery system, but we should still spend a short time discussing the impact of different charging solutions on the battery. Battery charging is typically referred to as level 1, level 2, or level 3 charging ( Table 1 ). In essence, this refers to the voltage being used to charge the battery. The EV charger is also sometimes referred to as the electric vehicle supply equipment (EVSE). Table 1: Charging levels The impact on the battery of each of these levels is slightly different.
For instance, level 1 charging is the easiest for the battery to use at it has very low c-rate charging. It is also about the standard voltage level in most US households, which means that you can charge your EV from a standard household outlet. Most EV manufacturers include level 1 chargers with the vehicles and have integrated the standard SAE level 2 connectors. Level 2 charging is the most commonly used as it is about the same voltage as most house- hold and industrial businesses. Level 2 charging is relatively safe on the battery as it will still Voltage (V) Current (A) Power (kW) Type Level 1 110 16 1.9 AC Level 2 208/240 32 19 AC Level 3 480 400 240 DC