Normally I develop electronics for clients and none of that development will become public, however every now and then a client says; share what you like in order to help others use this technology ( projects derivatives of that ended up open source; like my DieBieMS BMS and Ethercat interface DieBieSlave ). This year I have the luck / opportunity offered by a client who had me make a CCS interface based on the Lumissil PLC modem to also use my experience to create an open variant of it. The project of the client was a CCS EVCC to charge a tender yacht with an on shore / inside a host yacht DC charger, so much similarities!
The project that I intend to realise is more ambitious than I probably should have made it, but hey it's the start of the project and I am still optimistic . My careful optimistic estimate for the first prototype to be realised in 6 months. I will vlog the progress here and am open for all the criticism and hints / desires to make it applicable for use in EV conversions. My goal for the interface is to be able to V2G projects to solve energy challenges that are rising everywhere around us, this will require the interface to be able to act as a EVSE and EVCC. Although looking at the CCS might look like only a few wires, the reality of the interfacing is very wiring intensive. With this project I would like to cover everything, from driving all motors and relays to interfacing with the car / BMS to actuating the relays and measuring the voltages and currents.
I made a messy list of all interfacting items that I would like to include on the interface:
- CCS Interface
- Proximity Pilot
- Resistance reading
- Control Pilot
- PWM Duty Generation
- PWM Duty measurement
- PWM Peak voltage reading
- Resistive loading system
- Power line communication
- Connector locking
- Motor output
- Position sensor input
- Temperature sensing
- Two channels
- Connector unlock pushbutton
- Charge status RGBW Led
- Vehicle Interface
- Constant 12V power input
- OnOffSignals
- OUT - Connector present
- OUT - Charging active
- IN - Central door lock
- IN - Ignition
- Data
- CAN Vehicle
- ISO SPI Analog devices to go to battery interface
- Mechanical Charge door actuator
- Motor output
- Position sensor input
- Battery Interface
- Voltage sensing
- CCS Connector
- Battery
- Current sensing
- Charge port current
- Temperature sensing
- Four channels NTC
- Contactor control
- Negative contactor
- Positive contactor
- Networking Interface
- RJ45 Ethernet
- Single pair Ethernet
- USB
- one
- BTS710404ESAXUMA1 To drive the main contactors
- TLP223JD4TP1F To decouple the voltage sensing network from the HV lines when disabled
- TPS65131RGER To generate the symmetrical power supply for the PWM generation
- MT52L256M32D1PF The memory for the processor below
- DRV8876RGTR To drive the locking motor and door lock
- ADIN2111BCPZ To talk a modern single pair ethernet way with other devices
- LT3507AEUHF Main power supply will accept the continues input power 7 to 18V and generate 5V, 3.3V for the core components and 3.3V for interfacing items.
- STM32MP157CAA3 Will run linux for the ISO15118 protocol and ethernet interfacing, and the M4 core will handle the low level realtime items like the motors and LED's + CAN
- RTL8201F Ethernet controller
- STPMIC1CPQR Will provide the STM32MP1's power rail needs
- IS32CG5317 The main PLC Modem