Smart Multi-User EV Charging System

SMART MULTI-USER EV CHARGING SYSTEM

The EVOLUTE™ is a Smart Multi-User Electric Vehicle Charging System, designed and developed to address the unique challenges associated with deploying Electric Vehicle Supply Equipment (EVSE) in both new and existing Multi-User Residential Buildings (MURBs). Currently, the main challenges facing this sector are limited capacity, remote control, billing, and consumer freedom. While other systems address some of these issues, the Evolute is the only system that addresses all four. The Evolute’s advantage over other systems is its agnostic charging station compatibility; this gives consumers full freedom of choice, while still providing an interactive app to control, monitor and pay for usage. The Evolute software includes a cloud-based dashboard for administrators and management, with tools for remote control, monitoring, billing, and account management.

Cost of Infrastructure – In a retrofit Condo, only owners tapping into the system will pay for it. The cost of a 20 or 32 vehicle system can be divided amongst all users. The Condominium can charge end-users a one-time connection fee that represents 1/20 or 1/32 of the cost of the supply and installation. In a new construction Condo, the cost per parking spot of the system represents a fraction of the potential sell price for an EV ready parking spot. In new and existing rental and commercial buildings, the corporation can charge substantial monthly fees in addition to the electricity consumption costs.

Evolute is designed, developed, and manufactured in North America using cutting edge innovation and technology.

Powered with Eaton Technology, Intelligence by EVdirect

KEY FEATURES

COMPATIBILITY

All Level II charging stations are compatible with the Evolute system, as well as all standard 250V receptacles, such as NEMA 14-50, 6-50 etc.

SMART MULTI-METERING

Built-in individual smart meters track the usage of each owner’s consumption as well as the entire system. The data is stored in a secure Canadian-based cloud server.

SURGE PROTECTION - OPTIONAL

The entire system and downstream charging stations are protected from unwanted electrical surges that may occur in the building. Many buildings already have system wide protection.

SEAMLESS OPERATION

A dedicated internet connection drives the Evolute’s communication. In the unlikely event that the building’s internet goes down, charging and load management will be uninterrupted. Once restored, all data and billing info will be available to view.

LOAD MANAGEMENT

The Evolute’s sophisticated algorithm can be pre-set or adjusted in the future to meet a variety of load sharing ratios and minimum acceptable standards. Typical multipliers include 2X, 3X and 4X existing available power and distributing it fairly over an 8-12hr period.

TOTAL CONTROL

Owners and system administrators can access their data though a user- friendly desktop or mobile application. The Evolute App gives each owner full ON/ OFF control of their charging station from any device.

MONITORING + BILLING

The automated billing platform is seamless and easy to set up. The Evolute is flexible and can charge owners based on time-of-use or flat rate, depending on the building’s preferences.

NO CONTRACTS + FREE DATA

Data is free and always accessible to administrators and third-party billing companies at no extra cost.

There are no contracts to sign and rates can be adjusted at any time.

HOW IT WORKS

SYSTEM FLOW

The EVOLUTETM is connected to the main switchboard in the main electrical room with a new or existing fused switch. All system components are installed in an unused corporate space in the garage, storage room or anywhere feasible.

IMPLEMENTATION

Site visit and audit of electrical systems is arranged
Proposal, load assessment, drawings and an estimate are given to the board
Board meetings, Zoom meetings, and owner’s meetings are scheduled
Owner’s survey is sent out to determine interest and adoption
Interested owners provide parking spaces and specifics for a “Last Mile” estimate
Management confirms all owners participating in initial bulk install
EVdirect electricians begin the system and end-user installation
System is energized, commissioned and inspected by ESA

OWNER ACCESS

On-boarding email received
Account/passcode created
Fees paid
Station energized
Charging begins

EVOLUTE PRODUCTS

EVOLUTE EVO-40042

SPECIFICATIONS

400A, 42cct, 208Y/120V 3Ph 4W 72”H x 28”W x 5.75”D Main Lugs – Bottom Cable Entry

HARDWARE/SOFTWARE – cUL/CSA

Multi-Metering Module
Breaker Control Bus
Admin Dashboard
Fixed CT Rails
Ethernet Gateway
End-user App

Max panel capacity vs Max active charging	20 CAR CAPACITY	Maximum Simultaneous Charging
Voltage / kW	208V	6.66kW	8.32kW
EVSE Breaker Size		40A Breaker	50A Breaker
When using a Step-down Transformer	75 kVA	10	6
When using a Step-down Transformer	112.5 kVA	15	12
When using a Main Breaker @ 208-240V	200A	7	6
	250A	9	7
	400A	15	12

EVOLUTE EVO-60072

SPECIFICATIONS

600A, 72cct, 208Y/120V 3Ph 4W
90”H x 28”W x 5.75”D
Main Lugs – Bottom Cable Entry

HARDWARE/SOFTWARE – cUL/CSA

Multi-Metering Module
Fixed CT Rails
Breaker Control Bus
Ethernet Gateway
Admin Dashboard
End-user App

Max panel capacity vs Max active charging	32 CAR CAPACITY	Maximum Simultaneous Charging
Voltage / kW	208V	6.66kW	8.32kW
EVSE Breaker Size		40A Breaker	50A Breaker
When using a Step-down Transformer	112.5 kVA	15	12
When using a Step-down Transformer	150 kVA	20	15
When using a Main Breaker @ 208-240V	400A	15	12
	500A	19	15
	600A	24	19

DYNAMIC LOAD THROTTLING ARCHITECTURE RESPONSE SYSTEM

HOW DOES IT WORK

Dynamic Load Throttling Architecture Response System (DLTARS) allows more charging stations to be installed than the peak capacity of the building can handle. DLTARS monitors the main electrical service of the building and dynamically throttles down/up the Evolute’s upper power limit during peak circumstances. All Evolute panels are networked together with Cat5 wiring, they communicate with each other, and throttle limits based on live active users. Once power in the building goes below the preset values, all Evolute panels will function normally.

FUNCTIONALITY

A single master panel will communicate with any number of auxiliary panels to control their load shedding thresholds. Each panel, including the master panel, can still operate individually and separately from DLTARS if desired. Additionally, panels do not need to be the same size or capacity, as the system will dynamically adjust load shedding limits based on each panel’s preset configuration.

LOAD SHEDDING ALGORITHM

The dynamic load shedding algorithm is based on the defined amps limit of the building. A soft current limit for the entire DLTARS system is then set at 80% of this building limit. Furthermore, the load shedding limit for each individual panel will begin to lower exponentially after monitored building current is seen exceeding 85%** of the soft limit (**percentage subject to change). Finally, the logic will dynamically adjust individual upper load limits based on each panel’s load capacity and active users.

FRONTEND CONTROL

DLTARS can be activated and controlled from the Evolute web-app. Here, the max amps that a building is rated for can be set for determining the dynamic load shedding thresholds mentioned previously. Toggles for turning on and off the system for all or individual panels can also be switched to tailor the system for each building implementation.

WHEN TO IMPLEMENT THE DLTARS SYSTEM

The DLTARS system can be installed at the same time as the Evolute panel installation or later as a retrofit. Hardware and software components can be added at any time. The same applies for the interconnected wiring, it can be added at any point that makes sense for both existing and new construction applications. DLTARS should be implemented when there is a concern that the existing power within a building will not be sufficient for demand based on peak values.

EVOLUTE INTELLIGENT SOFTWARE

The Evolute’s load shedding algorithm is the primary focus of the panel’s functionality. The panel will cycle through users over a predefined cycling time, permitting a limited number of vehicles to charge at any given time. However, all actively charging vehicles will not be throttled to a lower current limit, and will instead allow for maximum current flow in exchange for fewer active loads. The number of vehicles permitted to charge is based on a preset upper current limit for each phase of the panel, where this threshold will not be exceeded.

Each Evolute has a certain amount of power allocated to it for EV charging, typically this power is enough to allow half, a third or a quarter of the total connected cars to charge simultaneously. When the upper power limit is reached, the next car that comes to charge will be placed in a queue, and 2 parameters must be met before that car will start charging; 1) Is the car requesting power? 2) Have connected cars achieved a pre-established initial block of energy? If the answer is Yes to both, the car that started charging first, in relation to all other cars, will be removed from the power, allowing the new car to start charging. The new car will have an opportunity to achieve its block of energy before it is removed, if need be. The car that was removed now enters its queue for sharing. Cars will be rotated around in this way throughout the charge cycle of 8 to 12 hours, ensuring that all cars receive a minimum of 50% of the total charge cycle. Cars will remain connected and charging if the upper limit of each panel is not reached and will only drop off when the battery is full, or the owner disconnects their car.

PROGRAMMABLE LOGIC CONTROLLER

The PLC controls all aspects of the panel’s automated functionality. It is connected via ethernet connection to the meter to receive data about power usage throughout the panel. It then uses this information for managing what breakers are enabled or disabled at a given time, while gradually cycling through users based on the implemented load shedding algorithm and current user configurations. The PLC also receives commands from the frontend control allowing loads to be remotely controlled and monitored

GATEWAY

The Gateway is a separate device, isolated from the main Evolute panel, and connected via another ethernet connection. It serves as the primary link between the PLC and the Evolute cloud server. This server connection allows for data from the panel to be stored in the cloud and accessed remotely by users. The gateway also has local storage to prevent data loss during internet or power outages. Additionally, the Gateway allows for user control to be passed from the user webapp to the PLC.

SOFT BREAKER IMPLEMENTATION

To avoid overcurrent scenarios and tripping the physical thermal breaker, software-based breakers have been implemented to control automatic disabling of the remote-controlled breakers. In the event that a breaker is automatically disabled, an email alert is sent to the support team. Once the issue has been resolved the breaker can be turned on remotely by a superuser. By default, these soft breakers are set to be triggered if the detected current through a given breaker exceeds 5% of its upper limit. In the case where a 40A breaker installed, the breaker is disabled if readings exceed 32A + 5%. The 5% threshold can be adjusted depending on the scenario.

APPLICATION VISUALIZATIONS

UNDERSTANDING TIME-BASED SHARING FOR EV CHARGING INFRASTRUCTURE USING A STANDARD 40A BREAKER, DELIVERING 32A @ 208V = 6.7kW

The main issue surrounding EV infrastructure is limited power, the question is how to take the available power and optimize it without affecting EV drivers’ ability to charge when they need to, and drive as they please. One hour of charging at 6.7kW = 6.7kWh; this is a function of power consumed over time. The Evolute™ System is designed to deliver full power (6.7kW) during a charging session, as the power-sharing aspect is related to how much time or kWh each user will receive during a typical charging period. Based on a 12 hour span from 6PM to 6AM, and a 1:2 ratio (meaning doubling available power), each user can expect to receive a minimum of 6 hours at full amperage, resulting in 40kWh per day. It is rare that an EV driver would require this amount of charge time per day, which leads to the discussion around further optimization of time per driver. The Toronto and Vancouver Green Standards have narrowed down their minimum requirements to 16kWh and 12kWh during an 8 hour period. At full delivery of power (6.7kW), it will take 2-2.5hrs of charging to achieve these green standards, leaving lots of time to share the remaining available power. Other ratios may better suit the needs of the condo, all depending on how much available power there is and how to distribute it fairly and economically to as many cars.

Below are examples of how many cars can be connected to a power source with different ratios of time-based power-sharing
Available Power			No Sharing	2 x Sharing	3 x Sharing	4 x Sharing	Toronto Green Standard Minimum Requirements 16kWh over 8hr period	Vancouver Green Standard Minimum Requirements 12kWh over 8hr period
kVA	kW	100% Amps @ 208v	Minimum guaranteed block of time/kWh that each user will achieve if all users were to charge simultaneously for a 12 hour period. On average EV drivers are only charging 1-3 hrs per night, 3-4 times a week, leaving a lot more power for those who require it.
kVA	kW	100% Amps @ 208v	12hrs = 80kWh	6hrs = 40kWh	4hrs = 26.8kWh	3hrs = 20kWh	3.6hrs = 24kWh (over a 12hr period)	2.7hrs = 18kWh (over a 12hr period)
75	67	208	10	20	30	40	33	44
100	90	278	13	27	40	53	45	60
112.5	101	312	15	30	45	60	50	67
150	135	416	20	40	60	80	67	90
175	157	485	23	47	71	94	78	104
200	180	555	27	54	81	107	90	120
225	202	625	30	60	90	120	101	134
250	225	695	33	67	102	134	112	150
275	248	765	37	74	112	148	124	165
300	270	830	40	80	120	160	135	180
350	315	970	47	94	143	188	157	210
400	360	1110	54	108	163	215	180	240
450	405	1250	60	121	184	242	202	270
500	450	1385	68	136	204	269	225	300
550	495	1525	74	148	225	296	247	330
600	540	1665	81	162	245	323	270	360
650	585	1800	87	175	265	350	292	390
700	630	1945	94	189	286	377	315	420
750	675	2080	101	202	306	404	337	450
800	720	2220	108	216	327	431	360	480
850	765	2360	114	228	347	458	382	510
900	810	2500	121	243	368	485	405	540
950	855	2635	128	256	388	511	427	570
1000	900	2775	135	270	405	538	450	600

UNDERSTANDING SHARING RATIOS AND SIMULTANEOUS CHARGING ON A PANEL LEVEL

	EVOLUTE-40042 400A rated		EVOLUTE-60072 600A rated
Max panel capacity vs Max active charging	20 CAR CAPACITY	Maximum Simultaneous Charging		32 CAR CAPACITY	Maximum Simultaneous Charging
Voltage / kW	208V	6.7kW	8.3kW	208V	6.7kW	8.3kW
EVSE Breaker Size		40A Breaker	50A Breaker		40A Breaker	50A Breaker
When using a 600-208V Transformer	75 kVA = 208A	10	8	112.5 kVA = 312A	15	12
When using a 600-208V Transformer	112.5kvA = 312A	15	12	150 kVA = 416A	20	16
When using a Main Breaker @ 208V	200A@80% = 160A	7	6	400A@80% = 320A	15	12
	250A@80% = 200A	9	7	500A@80% = 400A	19	15
	400A@80% = 320A	15	12	600A@80% = 480A	24	19

20 Vehicle System
EVOLUTE-40042 using 40A breakers

Various Transformer and/or Breaker sizes	75kVA = 208A	112.5kVA = 312A	200A = 160A	250A = 200A	400A = 320A
Simultaneous users	10	15	7	9	15
Waiting in queue	10	5	13	11	5

Total # of users	20	20	20	20	20
Sharing ratio	1:2	1:1.3	1:3	1:2	1:1.3
Adding a 10 user Auxiliary panel to share the same power
Simultaneous users	10	15	7	9	15
Waiting in queue	20	15	23	21	15

Total # of users	30	30	30	30	30
Sharing ratio	1:3	1:2	1:4	1:3	1:2
Adding a 20 user Auxiliary panel to share the same power
Simultaneous users	10	15	7	9	15
Waiting in queue	30	25	33	31	25

Total # of users	40	40	40	40	40
Sharing ratio	1:4	1:2.6	1:5.5	1:4	1:2.6

Smart Multi-User EV Charging System