The rapid ascent of new energy vehicles (NEVs) has brought the development of charging infrastructure into sharp focus, emerging as a critical pillar supporting the growth of the NEV industry. As the automotive sector hurtles toward electrification, connectivity, and intelligence, the demand for efficient, safe, and smart charging solutions has never been more pressing. Addressing the long-standing challenges of existing charging piles—such as the inability to enable remote management, control, and data collection—a team of researchers has unveiled an innovative intelligent management device for orderly charging of electric vehicles, set to redefine the landscape of EV charging.
This groundbreaking device, a product of meticulous engineering and collaborative research, is designed to seamlessly integrate with existing charging piles while adhering to national standards. Its core components, the Data Transfer Unit (DTU) and the Charging Management Controller, work in tandem to bridge the gap between scattered charging infrastructure and centralized management systems, unlocking a new era of intelligent charging.
The Need for Innovation: Tackling Charging Infrastructure Limitations
Traditional charging piles have long operated in relative isolation, lacking the capability to communicate with a central server or enable remote oversight. This disconnect has led to inefficiencies in energy distribution, difficulties in monitoring charging statuses, and challenges in managing peak loads—issues that become increasingly pronounced as the number of EVs on the road surges. For users, this often translates to unpredictable charging experiences, with no real-time visibility into charging progress or potential issues. For administrators, it means a lack of control over energy allocation, leading to wasteful consumption during peak hours and heightened risks of overloads.
The new intelligent management device directly addresses these pain points by establishing a robust communication network that connects individual charging piles to a central server. This network not only facilitates remote control but also enables the real-time collection and transmission of critical data, laying the foundation for optimized charging schedules and enhanced user experiences.
Inside the Device: The Dynamic Duo of DTU and Charging Management Controller
At the heart of this innovation lies a sophisticated interplay between two key components: the Charging Management Controller and the DTU. Each plays a distinct yet complementary role, ensuring seamless data flow, precise control, and reliable operation.
The Charging Management Controller: The Brain Behind Charging Operations
Installed between the charging box and the charging gun, the Charging Management Controller serves as the operational hub of each charging point. Its design is a masterclass in functionality, packing a range of capabilities into a compact form factor. Equipped with an embedded controller, a clock chip, an RS-485 communication interface, an energy metering module, and control relays, it is engineered to monitor, record, and regulate every aspect of the charging process.
The controller’s ability to measure and log critical data points is a game-changer. It tracks the start and end times of charging sessions, real-time current and voltage, total energy consumed, and the real-time status of the charging pile.—information that is invaluable for both users and administrators. This data is not merely collected but is actively used to inform decision-making, with the controller capable of adjusting charging parameters based on commands received from the server.
One of its standout features is its ability to control the charging current, allowing it to either facilitate normal charging or switch to a minimal current (6 A) when needed. This flexibility is crucial for balancing energy loads across multiple charging points, ensuring that the grid remains stable even during periods of high demand.
The hardware design of the Charging Management Controller is equally impressive. The energy metering module, utilizing the SUI-101A high-precision multifunctional AC transmitter, guarantees accurate measurements of AC current, voltage, and cumulative energy. Meanwhile, the K3 and K4 relays are designed to remain disconnected when the controller is not in operation, ensuring that the normal functioning of the charging pile remains unimpeded—a critical fail-safe mechanism.
On the software front, the controller operates on a structured logic that ensures reliability and efficiency. It communicates with the DTU using the MODBUS protocol, adopting a master-slave architecture where the DTU acts as the master station and the controller as the slave station, with addresses ranging from 1 to 255. This setup allows for systematic data retrieval and command execution, with the master station polling slave stations at regular intervals to gather data or issue control instructions.
The controller’s operational logic is a testament to its precision. It reads its address from an 8-bit address encoder, continuously collects data from the energy module, and stores information about phase lines using a 2-bit phase encoder. It determines charging start and end times based on voltage changes at the inlet, monitors real-time charging status via outlet voltage detection, and responds to commands from the DTU by adjusting the state of the K3 and K4 relays—all while maintaining seamless communication.
The DTU: The Nervous System of Data Transmission
If the Charging Management Controller is the brain of the operation, the DTU is its nervous system, facilitating the critical flow of data between the charging piles and the central server. Its primary function is to act as a bridge, enabling bidirectional communication that is essential for remote management and control.
The DTU’s hardware design is tailored to handle multiple connections simultaneously, featuring 12 RS-485 communication ports (com1 to com11 and comz). These ports connect to individual charging management controllers (com1 to com11) and the community’s total basic load energy meter (comz), ensuring comprehensive data collection from both charging activities and the broader electrical grid. Each port is equipped with 4 wires—two for power (GND/24 V) and two for signal transmission (A/B)—providing both power and communication capabilities to connected devices.
Software-wise, the DTU operates on a well-orchestrated schedule to ensure timely data exchange. It polls each charging management controller every 60 seconds using the MODBUS protocol, collecting real-time data on charging statuses and storing this information in corresponding registers. Every 15 minutes, it communicates with the host computer (server), transmitting the accumulated data and receiving control commands. These commands are then relayed to the respective charging management controllers, enabling centralized adjustments to charging operations.
A key feature of the DTU is its ability to monitor communication health. If it fails to receive a response from a connected device, it flags the issue by setting the corresponding register to 0, while a successful communication sets the register to 1. This transparency allows administrators to quickly identify and address connectivity problems, minimizing downtime.
How It All Comes Together: The Integrated System
The true power of this intelligent management device lies in its seamless integration, creating a cohesive ecosystem that connects charging piles, the DTU, and the central server. The physical connections are designed for both functionality and ease of installation, ensuring that the system can be deployed with minimal disruption to existing infrastructure.
The DTU serves as the central node, connected via an Ethernet cable to an internal network switch or directly to a computer, enabling high-speed data transmission to and from the server. It interfaces with a three-phase energy collection module through a 4-core aviation connector to gather data on the community’s basic electrical load, a critical input for balancing energy distribution.
Each Charging Management Controller is linked to the DTU via another 4-core aviation connector, which provides a 12 V power supply and facilitates communication through the RS-485 interface. The controller, in turn, connects to both the charging gun and the charging pile, forming a closed loop that enables real-time monitoring and control of the charging process. The entire system is powered by a 220 V power supply, ensuring stable operation.
This integrated structure ensures that data flows freely between all components: the Charging Management Controllers collect and send real-time charging data to the DTU, which aggregates this information along with community load data and transmits it to the server. The server then processes this data, optimizes charging schedules, and sends control commands back through the DTU to the respective controllers, which adjust their operations accordingly. This feedback loop creates a dynamic system that responds in real time to changing conditions, ensuring efficient and orderly charging.
Transforming the EV Charging Experience
The impact of this intelligent management device extends far beyond technical innovation, directly enhancing the user experience and operational efficiency. For EV owners, the ability to remotely monitor charging status—including real-time current, voltage, and remaining time—eliminates uncertainty, allowing them to plan their schedules with greater confidence. The transparency provided by the system also builds trust, as users can easily track their energy consumption and associated costs.
For administrators and utility companies, the benefits are equally profound. The centralized management platform enables precise control over each charging pile, allowing for the optimization of charging times to avoid peak load periods. By analyzing data on energy consumption patterns, administrators can make informed decisions about infrastructure expansion, ensuring that charging capacity keeps pace with demand.
The system’s ability to distribute energy intelligently also contributes to grid stability. During periods of high demand, the server can issue commands to reduce charging currents or temporarily pause non-essential charging, preventing overloads and ensuring a reliable supply of electricity for all users. This not only reduces the risk of blackouts but also lowers operational costs by minimizing the need for expensive grid upgrades.
Looking Ahead: The Future of Intelligent Charging
As the NEV market continues to grow, the need for smart charging infrastructure will only intensify. This intelligent management device represents a significant step forward, but its potential extends beyond its current capabilities. Future iterations could incorporate artificial intelligence algorithms to predict charging demand more accurately, further optimizing energy distribution. Integration with renewable energy sources, such as solar or wind power, could also make the charging process more sustainable, aligning with global efforts to reduce carbon footprints.
The device’s adherence to national standards ensures compatibility with existing and future charging infrastructure, making it a scalable solution that can grow with the industry. Its modular design also allows for easy upgrades, ensuring that the system can adapt to new technologies and evolving requirements.
In a world where the transition to electric mobility is no longer a choice but a necessity, innovations like this intelligent charging management device are critical enablers. They not only address the immediate challenges of charging infrastructure but also lay the groundwork for a more connected, efficient, and sustainable transportation ecosystem.
About the Research Team
This innovative device is the result of collaborative research by Yuanbin Liu, Yihao Zhao, Xuezhong Fan, Lingxin Kong, Renfeng Yue, and Yan Su. The team comprises researchers from leading institutions and companies, including the School of Control Science and Engineering at Shandong University, Qilu University of Technology (Shandong Academy of Sciences), Shandong Aipu Electric Equipment Co., Ltd., Shandong Electric Engineering Group Co., Ltd., Shandong Aipu Electric Equipment Co., Ltd. Jinan High-Tech Branch, and State Grid Shandong Jinan Licheng District Power Supply Company.
Their work, published in the journal Technology Innovation and Application (2024, Issue 17, DOI: 10.19981/j.CN23-1581/G3.2024.17.012), exemplifies the power of cross-institutional collaboration in driving technological advancement, offering a glimpse into the future of intelligent transportation.