To combat climate change and transition to a sustainable future, widespread adoption of electric vehicles (EVs) is crucial. While EV production continues to increase and consumers have shown an interest in switching to EVs, the availability of fast-charging infrastructure remains a barrier. As a result, many governments have adopted programs and incentives to fund the production and installation of EV charging infrastructure.
As EV infrastructure engineers and manufacturers work to quickly scale production to support growing demand, they cannot sacrifice quality and reliability. Drivers around the globe depend on the longevity and availability of this infrastructure. By prioritizing resilience and sustainability, we can create an EV charging infrastructure that supports the transition to a future with cleaner and more reliable transportation.
Below are some critical components manufacturers need to examine in their EV infrastructure designs to drive improved resilience and sustainability.
Power connections
Power connections connect all electrical systems in EV installations, such as the connections between EV charging stations and the inverter, the connection from the energy storage system to the inverter, or the solar PV arrays to the energy storage system (Figure 1). Proper and reliable power connections are critical for the system’s overall resilience.
Figure 1. Integrating renewables and energy storage with EV infrastructure helps drive net-zero goals, but only if these electrical systems are connected properly.
When it comes to power connections, using high-quality lugs and certified tools is essential. Lugs, which are connectors used to terminate and connect electrical cables, must be properly installed to maintain a secure and efficient electrical connection.
Certified tools, designed explicitly for crimping and securing lugs, ensure the connections are made with the correct pressure and precision, reducing the risk of loose connections, overheating, and potential electrical failures. By adhering to industry standards and using certified tools, installers can significantly enhance the durability and performance of electrical systems, ultimately contributing to a safer and more reliable power infrastructure.
Lightning and surge protection
EV charging systems are advanced electrical installations that people will interact with daily, making electrical safety extremely important. As EV infrastructure expands, charging installations will also be located in more remote environments, sometimes exposed to harsh conditions, making lightning protection a critical need to protect people, infrastructure, and vehicles.
Lightning protection design is not a one-size-fits-all engineering challenge. In some cases, lightning protection specifically for EV charging is unnecessary because charging stations fall under the zone of protection from other local buildings. In other instances, installers must design lightning protections for their charging stations. When doing so, there are several choices.
Traditional lightning protection includes passive protection from grounded lightning rods. Still, in many cases, active protection systems that proactively draw strikes away from electrical equipment can be a better choice because of their reliability and large zones of protection. Active protection can also reduce the total cost of ownership.
Grounding and bonding
All electrical systems require proper surge protection and grounding. Current always flows through the path of the lowest impedance, and even the most well-designed electrical systems can be at risk from fault currents from lightning, equipment malfunctions, or surges from power sources.
Good grounding and bonding systems consider soil conditions, seasonal patterns, and other unique site differences. This improves safety for people working with and around EV charging installations while maintaining the reliability of this critical equipment (Figure 2).
Figure 2. EV charging installations are complicated systems — ensuring they’re properly protected is critical to maintaining reliable infrastructure.
To ensure their effectiveness, EV charging stations must follow best practices for proper bonding and grounding, considering site locations, soil resistivity levels, and corrosion levels. Based on these factors, different types of connections, such as mechanical, compression, or exothermic, may be required to ensure the grounding and bonding systems work effectively. Manufacturers need to find grounding and bonding partners to support them through a design process tailored to their site conditions.
Enclosures and thermal management
Enclosures play a pivotal role in enhancing the resiliency of EV charging infrastructure by protecting sensitive electrical components and keeping them operational under various conditions. Enclosures protect equipment against environmental factors such as extreme temperatures, moisture, dust, and debris. This protection is essential for maintaining the functionality and longevity of the equipment, especially in outdoor or exposed locations.
Additionally, enclosures enhance safety by preventing accidental contact with live electrical parts and containing potential electrical fires or sparks, thereby reducing the risk of fire spreading. They also offer physical security against vandalism and theft, ensuring only authorized personnel can access the internal components.
Enclosures equipped with advanced thermal management systems, such as liquid cooling, also help manage the heat generated by high-power components, preventing overheating, and ensuring efficient operation. Compliance with industry standards and regulations is a critical consideration, as certified enclosures meet legal and insurance requirements, contributing to the safe operation of EV charging stations.
By protecting internal components from environmental and physical damage, enclosures significantly enhance the reliability and resiliency of EV charging infrastructure, ensuring continuous operation and consistent service to EV users. This reliability is essential for supporting the growing demand for electric vehicles and promoting sustainable transportation systems.
A sustainable future
The increased use of EVs presents opportunities to build a more sustainable future and create a more resilient and reliable global transportation infrastructure. But first, hardware and site integrators must prioritize sustainability and safety for installers and end users in every phase of their design and planning process.
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