EV Charging Board Requirements Capture
Source
- Uploaded requirements PDF reviewed and consolidated into project requirements.
Functional Requirements
- Single phase AC input: 220 V AC nominal.
- Maximum charging output: 11 kW / 50 A.
- Two-level control architecture:
- Real-time charging/control board based on STM32H743VIT.
- Upper control/communications board based on Radxa ROCK4D.
- Vehicle interface shall implement CP/PP behavior aligned with IEC 61851.
- Upper board integration shall support system-level ISO 15118 / OCPP architecture.
- System shall report status to the upper board every 100 ms.
Safety Requirements
- GFCI residual current detection threshold: 30 mA.
- GFCI trip response time: ** SPD -> EMI filter -> NTC/inrush limiting -> GFCI CT -> contactor -> weld monitor -> EV output
- Vehicle interface:
- CP with State A/B/C/D/E/F handling
- PP detection for cable/current qualification
- diode presence / abnormal negative-voltage detection required before enabling contactor
- Board-to-board/control interfaces:
- Ethernet identified between charging board and ROCK4D in source concept
- system status, authorization, current limit, fault flags, and mode control required between boards
- Power rails identified in source concept:
- 24 V
- 5 V
- 3.3 V
- 1.8 V
- +/-12 V for CP circuitry
Architectural Blocks
1. Power Conversion and System Protection Block
- AC input protection
- surge protection
- EMI filtering
- inrush limiting
- residual current sensing
- contactor switching
- weld detection
- low-voltage auxiliary power generation
2. EV Interface Block
- CP generation and measurement
- PP detection
- EV connector interface
- diode presence / negative-voltage safety check
3. Real-Time Control Board
- safety interlock
- contactor control
- ZCD processing
- GFCI processing
- CP/PP state handling
- energy and analog measurement
- local fault latching and immediate shutdown
4. Upper Control Board
- charging authorization
- communications
- ISO 15118 / OCPP stack hosting
- billing / logging / HMI / service coordination
Normal Operating Scenario
- AC input valid and auxiliary rails available.
- Real-time board validates ZCD, AC window, temperature, flood, E-STOP, and no latched critical fault.
- CP/PP indicates valid vehicle connection and charging-ready state.
- Upper board provides charge authorization and current limit.
- Real-time board closes contactor with zero-cross synchronization.
- Charging continues with periodic status reporting and continuous safety monitoring.
Fault / Protection Scenarios
- GFCI trip -> immediate contactor OFF.
- E-STOP active -> immediate safe shutdown.
- Flood detected -> charging inhibited and power-path shutdown action required.
- Weld detected after OFF command -> latch fault and alarm upper board.
- ZCD missing / AC abnormal -> stop charging.
- CP fault or invalid diode/negative voltage behavior -> prohibit contactor ON.
- Overtemperature -> warn then trip according to thresholds defined in source material.
Missing or Ambiguous Requirements
- Current-path part examples in source are inconsistent with 50 A operation; exact production ratings must be reconciled.
- Exact GFCI compliance scope is incomplete, including any 6 mA DC residual-current requirement.
- E-STOP implementation detail is incomplete: hardwired power removal vs logic monitoring, reset/latching policy, safety category.
- Contactor driver implementation detail is incomplete: driver topology, flyback/snubbers, coil current budget.
- PP resistor coding / cable-current mapping and tolerance windows are not fully specified.
- Board-to-board link behavior is not fully formalized: startup sequencing, timeout policy, retry policy, degraded operation when upper board is offline.
- Environmental and mechanical requirements are incomplete: ambient range, IP rating, creepage/clearance targets, PCB copper/current-carrying requirements, shock/vibration.
- Security requirements are incomplete: secure boot, firmware signing, key provisioning, debug lock policy.
- V2G is architectural/optional and not fully specified as an implementable charging-board requirement.
Verification Checklist
- Verify AC input and output power targets are documented.
- Verify all safety interlock inputs are enumerated.
- Verify CP/PP and EV connector interface requirements are captured.
- Verify board partitioning between real-time and upper control boards is documented.
- Verify power, signal, and control interfaces between blocks are defined.
- Verify fault scenarios and immediate shutdown conditions are listed.
- Verify regulatory/compliance targets are listed.
- Resolve ambiguous ratings for EMI filter, contactor, terminals, and wiring.
- Resolve incomplete GFCI, E-STOP, PP, and communication fail-safe requirements.
Compliance / Certification Targets
- IEC 61851-1
- IEC 62196-2
- ISO 15118-1/2
- IEC 60364-7-722
- IEC 61643-11
- CISPR 32 / KN32
- IEC 61000-4-x
- KC certification
- MID / OIML R46
- OCPP 1.6 / 2.0.1
Proposed Next Design Inputs
- Formalize current-path component ratings and margins.
- Freeze board-to-board interface contract.
- Define E-STOP, GFCI, flood reset, and weld-latch behavior in implementation detail.
- Capture mechanical, environmental, and isolation constraints before schematic entry.
Rev A RT-to-Upper Interface Capture Update
Completed RT-side schematic capture items
- Verified the frozen Rev A 40-pin interface baseline against the RT schematic capture documents and aligned the active connector implementation around J1.
- Completed Page 7 power-entry support around F1, C2, and D2, with duplicated
B2B_24V_IN pins now carried on connector pins 1 and 2.
- Completed Page 14 CAN interface capture using U1, L1, D1, and R1.
- Completed core Rev A fitted sideband hookups for
B2B_RT_READY, B2B_CHARGE_EN, and B2B_FAULT_OUT using R2, R6, and R7.
- Completed Rev A debug UART exposure for
B2B_DBG_UART_TX and B2B_DBG_UART_RX on connector pins 19 and 20.
- Added RT-side bring-up test points TP1 through TP11 for power entry, CAN bus, CAN logic side, sideband, and debug access.
Frozen Rev A omissions preserved intentionally
B2B_CAN_WAKE on pin 16 remains omitted.
B2B_CAN_STB_CTRL on pin 15 remains omitted.
B2B_SHIELD_GND on pin 30 remains omitted.
Remaining review observations
- ERC floating-pin warnings now correspond to intentionally unused, optional, or reserved connector pins that are not yet terminated or explicitly annotated with downstream board-policy graphics.
- Ground is currently represented on the RT schematic as the global
GND return network at the circuit level, while the frozen connector documentation still names the connector return role as B2B_GND. This is acceptable for RT local capture review but should be checked once the Upper board pages are fully aligned.
- Cross-board consistency review is functionally ready for the RT-side captured signals, but final freeze sign-off still depends on confirming the Upper board pages, optional/reserved pin marking conventions, and downstream physical test-point access.