Detailed description

Detailed description of how to connect to and test with the HIL Electric Vehicle Charging Interface.

Communication Connection

In order to test the ISO 15118 vehicle to grid communication, the following terminals of a charging plug must be connected to the corresponding CP-PP-PE connector on the HIL Electric Vehicle Charging Interface:

  • Control Pilot (CP)
  • Proximity Pilot (PP)
  • Protective Earth (PE)

Connection to the following charging plugs is supported:

  • CCS Combo Type 1
  • CCS Combo Type 2
  • J1772
  • Mennekes Type 2
  • Supercharger
Note: Please refer to your charger's documentation for the connectors for your specific charging plug type.

Connectors

To connect a signal, the same type of coil should be used for both the Power Amplifier and the EVSE. An example of the main connectors and which plugs they correspond to are shown in Table 1.

Table 1. Connectors
Signal Type Embedded Connector Connector Plug
AC signal

PN: 1821083

 -
DC signal

PN: 1228819

PN: 1155595

PN: 1228821

PN: 1155594

Additional information on all connectors and interfaces is provided in the Mechanical section.

Signal Reading Flexibility

The HIL Electric Vehicle Charging Interface enables signal reading either via HIL I/O signals or via CAN connected to the HIL device. Signals can be configured to transmit values through CAN communication or via DIN I/O cables. This functionality offers users the flexibility to potentially utilize less I/O signals and read signals via CAN. However, it's important to note that while this solution is convenient for signal management, readings via CAN may have a precision deviation of up to 1% accuracy and introduce a time delay of approximately (10 ms). Reading signals through HIL I/O ensures higher precision and real-time data acquisition.

The configuration of these signals can be performed on-request as a service by a Hardware Engineer from Typhoon HIL.

Table 2. Configuration-selectable signals
Pin Device Signal
AO5 P-HIL Connected_led
AO6 P-HIL Lock_led
AO7 P-HIL AC-Mode_led
AO8 P-HIL DC-Mode_led
AI7 P-HIL I_L1
AI8 P-HIL I_L2
AI9 P-HIL I_L3
AI10 P-HIL U_L1
AI11 P-HIL U_L2
AI12 P-HIL U_L3
AI13 P-HIL I_DC
AI14 P-HIL U_DC
AI15 P-HIL Lock_status
DO28 P-HIL DC_SW1
DO29 P-HIL DC_SW2
DO30 P-HIL AC_SW1
DO31 P-HIL AC_SW2

I/O Pinout

Note: The P-HIL Interface is connected to the HIL system via the C-HIL Interface using serial DIN cables. The P-HIL is exclusively connected to the lower row of DIN connectors on the C-HIL. Direct connection of the P-HIL with the HIL device is not possible; it must be routed through the C-HIL for proper functionality.

The following tables provide a pinout description for the interconnection of the device with the HIL system using DIN cables, Table 3 specifies which pins are used for Analog Output (AO), Analog Input (AI), Digital Output (DO), and Digital Input (DI) on the HIL device, while the subsequent tables explain the functions of each pin.

Table 3. I/O Occupation of HIL Devices
No. Function Usage in HIL System Comment
1 Analog Output (AO) 8 CCS interface 4, P-HIL 4
2 Analog Input (AI) 15 CCS interface 6, P-HIL 9
3 Digital Output (DO) 31 CCS interface 27, P-HIL 4
4 Digital Input (DI) 1 CP Scope in HIL
Table 4. Analog Output Pinout
Pin Device Signal Scale Comment
AO1 C-HIL - - CCS Interface
AO2 C-HIL - - CCS Interface
AO3 C-HIL - - CCS Interface
AO4 C-HIL - - CCS Interface
AO5 P-HIL Connected_led 1 The signal adjusts the brightness of the diode on the front panel, and indicates whether the EV HIL connect is connected to the EV.
AO6 P-HIL Lock_led 1 The signal adjusts the brightness of the diode on the front panel, and shows whether the CCS socket has been successfully locked using the actuator
AO7 P-HIL AC-Mode_led 1 The signal adjusts the brightness of the diode on the front panel, and shows that the device is in AC charging mode.
AO8 P-HIL DC-Mode_led 1 The signal adjusts the brightness of the diode on the front panel, and shows that the device is in DC charging mode.
Table 5. Analog Input Pinout
Pin Device Signal Scale Comment
AI1 C-HIL - - CCS Interface
AI2 C-HIL - - CCS Interface
AI3 C-HIL - - CCS Interface
AI4 C-HIL - - CCS Interface
AI5 C-HIL - - CCS Interface
AI6 C-HIL - - CCS Interface
AI7 P-HIL I_L1 See comment Current measurement of phase L1 scale from 0 to 50 Arms reading value from 0 V to 7.071 Vrms, where 50 Arms indicates a reading of 7.071 Vrms.
AI8 P-HIL I_L2 See comment Current measurement of phase L2 scale from 0 to 50 Arms reading value from 0 V to 7.071 Vrms, where 50 Arms indicates a reading of 7.071 Vrms.
AI9 P-HIL I_L3 See comment Current measurement of phase L3 scale from 0 to 50 Arms reading value from 0 V to 7.071 Vrms, where 50 Arms indicates a reading of 7.071 Vrms.
AI10 P-HIL U_L1 See comment Voltage measurement of phase L1 scale from 0 to ±500 Vrms reading value from -10 V to +10 V, where 500 Vrms indicates a reading of +10 V.
AI11 P-HIL U_L2 See comment Voltage measurement of phase L2 scale from 0 to ±500 Vrms reading value from -10 V to +10 V, where 500 Vrms indicates a reading of +10 V.
AI12 P-HIL U_L3 See comment Voltage measurement of phase L3 scale from 0 to ±500 Vrms reading value from -10 V to +10 V, where 500 Vrms indicates a reading of +10 V.
AI13 P-HIL I_DC See comment Current measurement DC scale from -250 A to 250 A reading value from -10 V to +10 V, where 250 A represents a value of +10 V.
AI14 P-HIL U_DC See comment Voltage measurement of DC scale from 0 to ±1500 Vrms reading value from -10 V to +10 V, Where 1500 Vrms indicates a reading of +10 V.
AI15 P-HIL Lock_status See comment The value depends on the type of CCS connector 24V or 12V.
  • For 12 V socket:
    • Open lock value is 5 V
    • Closed lock value is 0.73 V
  • For 24V socket:
    • Open lock value is 0 V
    • Closed lock value is 10 V
Table 6. Digital Output Pinout
Pin Device Signal Scale Comment
DO1 C-HIL - - CCS Interface
DO2 C-HIL - - CCS Interface
DO3 C-HIL - - CCS Interface
DO4 C-HIL - - CCS Interface
DO5 C-HIL - - CCS Interface
DO6 C-HIL - - CCS Interface
DO7 C-HIL - - CCS Interface
DO8 C-HIL - - CCS Interface
DO9 C-HIL - - CCS Interface
DO10 C-HIL - - CCS Interface
DO11 C-HIL - - CCS Interface
DO12 C-HIL - - CCS Interface
DO13 C-HIL - - CCS Interface
DO14 C-HIL - - CCS Interface
DO15 C-HIL - - CCS Interface
DO16 C-HIL - - CCS Interface
DO17 C-HIL - - CCS Interface
DO18 C-HIL - - CCS Interface
DO19 C-HIL - - CCS Interface
DO20 C-HIL - - CCS Interface
DO21 C-HIL - - CCS Interface
DO22 C-HIL - - CCS Interface
DO23 C-HIL - - CCS Interface
DO24 C-HIL - - CCS Interface
DO25 C-HIL - - CCS Interface
DO26 C-HIL - - CCS Interface
DO27 C-HIL - - CCS Interface
DO28 P-HIL DC_SW1 -

For opening and closing contactor DC_SW1. The contactors are in the initial state normally open (NO).

DO = 0 V, SW = Open

DO = 10 V, SW = Close
DO29 P-HIL DC_SW2 -

For opening and closing contactor DC_SW2. The contactors are in the initial state normally open (NO).

DO = 0 V, SW = Open

DO = 10 V, SW = Close
DO28 P-HIL AC_SW1 -

For opening and closing contactor AC_SW1. The contactors are in the initial state normally open (NO).

DO = 0 V, SW = Open

DO = 10 V, SW = Close
DO28 P-HIL AC_SW2 -

For opening and closing contactor AC_SW2. The contactors are in the initial state normally open (NO).

DO = 0 V, SW = Open

DO = 10 V, SW = Close
Table 7. Digital Input Pinout
Pin Device Signal Scale Comment
DI1 C-HIL - - CCS Interface
DI2 C-HIL - - CCS Interface
DI3 C-HIL - - CCS Interface
DI4 C-HIL - - With this pin, the current value of the CP (Control Pilot) signal can be read through the Scope.

CAN Message Information

Table 8 outlines the available CAN Bus control messages. These messages are used to monitor and control the CCS plug for safety or operation purposes. They provide essential feedback to ensure the system functions correctly and can respond appropriately to changing conditions.

Table 8. CAN Bus Messages
Signal Message ID R/W Value Start Bit Type Data Length Description
motor_lock 1 W 9 0x8 Int 8 bits Motor lock status (1: locked, 2: unlocked)
motor_Unlock 1 W 10 0x8 Int 8 bits Motor lock status (1: locked, 2: unlocked)
pt1000_dc_p_temp 1 R Temp 0x8 Float 8 bits Temperature of PT1000 sensor on DC+
pt1000_dc_n_temp 1 R Temp 0x10 Float 8 bits Temperature of PT1000 sensor on DC-
ptc_temp 1 R Temp 0x18 Float 8 bits Temperature of PTC sensor

A description of each variable is as follows:

  • motor_lock: This variable controls the locking mechanism of the motor. Setting motor_lock triggers the motor to move to the locked position (sets Motor lock status to 1).
  • motor_Unlock: This variable controls the locking mechanism of the motor. Setting motor_Unlock triggers the motor to move to the Unlock position (sets Motor lock status to 2).
  • pt1000_dc_p_temp: This represents the temperature measured by the PT1000 temperature sensor connected to the DC positive terminal. The variable pt1000_dc_p_temp holds the temperature value read from this sensor.
  • pt1000_dc_n_temp: This represents the temperature measured by the PT1000 temperature sensor connected to the DC negative terminal. The variable pt1000_dc_n_temp holds the temperature value read from this sensor.
  • ptc_temp: This represents the temperature measured by the PTC (Positive Temperature Coefficient) sensor. The variable ptc_temp holds the temperature value read from this sensor.