DIY electrical car charging cable

I have made earlier a post on electrical car charging cables and charging stations technology. This s a continuation posting related to it. This posting links to DIY projects related to electrical vehicle charging cables. Those cables are quite expensive, so some DIY persons have tried to make their own versions. Some even claims have succeeded on this project. But take all the instructions with grain of salt, as we are dealing with dangerous voltages, high current and expensive devices. Making any mistakes can potentially electrocute you, start a fire (in cable, car or wall wiring) or destroy expensive electronics inside your electrical vehicle.

Here are some videos on troubleshooting and repairing commercial cables:

Electric Car Charger Troubleshooting

Repairing a damaged EV charging cable.

EVSE Level 1 J1772 plug replacement

Here are some interesting looking DIY electrical vehicle charging projects:

Designing a better portable EV charger (granny charger)

Arduino based very simple DIY EVSE / Charging station

Homemade level 2 EV charger quick overview

Designing a better portable EV charger (granny charger)

open-evse is an open Hardware and Software for Charging J1772 compliant Electric Vehicles. The EVSE promises to provide the connection, communication and safety devices between the EV and the wall.

What is OpenEVSE

OpenEVSE build and mini-review

Building an OpenEVSE kit 3

#24 – Do-It-Yourself OpenEVSE level 2 electric vehicle charger – part 1

#25 – Do-It-Yourself OpenEVSE level 2 electric vehicle charger – part 2

DIY Level 2 EV Charger Part 1 – The J1772 Standard

DIY Level 2 EV Charger Part 2 – Designing the Hardware

DIY Level 2 EV Charger Part 3 – Programming and Testing

10 Comments

  1. Tomi Engdahl says:

    Energy Storage Systems Boost EV Fast-Charger Infrastructure (Part 1)
    With the EV market expected to dramatically rise in the near future, questions arise regarding how the electric grid can handle the load. Part 1 of this two-part series looks at the keys to building an infrastructure using energy storage systems.
    https://www.electronicdesign.com/markets/automotive/whitepaper/21131625/energy-storage-systems-boost-ev-fastcharger-infrastructure-part-1

    Energy Storage Systems Boost EV Fast-Charger Infrastructure (Part 2)
    In Part 2 of this two-part series, we will analyze the critical components of the charging station and how to address the specific challenges that arise in design.
    https://www.electronicdesign.com/markets/automotive/whitepaper/21133277/energy-storage-systems-boost-ev-fastcharger-infrastructure-part-2?utm_source=EG+ED+Auto+Electronics&utm_medium=email&utm_campaign=CPS200608042&o_eid=7211D2691390C9R&rdx.ident%5Bpull%5D=omeda%7C7211D2691390C9R&oly_enc_id=7211D2691390C9R

    Reply
  2. Tomi Engdahl says:

    Raspberry Pi EVSE Hat
    Use a Raspberry Pi to build an EV charging station
    https://hackaday.io/project/167595-raspberry-pi-evse-hat

    Reply
  3. Tomi Engdahl says:

    Vuorovirta-anturi sähköautojen latausasemiin
    https://etn.fi/index.php/new-products/11903-vuorovirta-anturi-sahkoautojen-latausasemiin

    Vuodesta 2016 lähtien IEC-standardit, tarkemmin sanoen IEC 62955 / IEC 62752, ovat edellyttäneet 6 mA:n DC-vuotovirran tunnistuskykyä kotitalouksissa vaadittavan Tyypin A vikavirtasuojan (RCD) toimimattomuuden estämiseksi. Tämä vika ilmenee, jos sähköauton latausasemassa on eristysvika.

    Sähköauton arkkitehtuuriin sisältyy akusto, jota syötetään tasavirralla (DC), josta voi muodostua kotitalouksissa käytettävän vikavirtasuojan (RCD) deaktivoiva vuotovirta. Vikavirtasuojan estämiseksi ja sähköautojen omistajien kotitalouksien sähköpaneeleihin muutoin tarvittavan Tyypin B vikavirtasuojan asennustarpeen välttämiseksi sähköautojen latausasemat on varustettu DC-vuotovirran tunnistavalla laitteella. Tämä tunnistus on CDSR:n tehtävä.

    https://www.lem.com/en/evs-chargers

    Reply
  4. Tomi Engdahl says:

    DehneEVSE – Open source EV charging station
    https://dehnes.com/electronics/2021/03/31/dehneevse_charging_station.html

    I designed and built my own EVSE EV Charging station from scratch because I wanted 2 stations with each 22kW support (3 phase, 400V, 32A) and “real-time” current & voltage measurements on all phases – in order to be able to do dynamic load sharing between the stations. E.g. if car-1 only uses 13A, the remaining 19A are allowed on the second station.

    It was a real full stack project, reaching from hardware/electronics design all the way to the frontend webapp written in TypeScript.

    Building your own charging stations is fun and gives you full control over the charging (assuming you like to code). It is also cheaper

    DehneEVSE Open source EV Charging Station – Firmware
    Arduino firmware (for Arduino Nano 33 IoT) for my DehneEVSE EV Charging Station.
    https://github.com/sebdehne/DehneEVSE-Firmware

    Reply
  5. Tomi Engdahl says:

    This Hacker Built His Own Open Source, Arduino-Controlled Electric Car Charging Station
    EV chargers can be very expensive, which is why Sebastian Dehne designed this custom charging station with an Arduino Nano 33 IoT.
    https://www.hackster.io/news/this-hacker-built-his-own-open-source-arduino-controlled-electric-car-charging-station-36602892374d

    Reply
  6. Tomi Engdahl says:

    Retrofitting Fast Charging To A Nissan Leaf EV
    https://hackaday.com/2021/06/28/retrofitting-fast-charging-to-a-nissan-leaf-ev/

    Electric cars have been around for a while now, and thus they’re starting to get chopped up and modded just like any other car. [Daniel Öster] is one such person doing the work, and recently posted his efforts to retrofit fast charging to an base-model Nissan Leaf that didn’t ship with the feature.

    It’s an involved swap, requiring the substitution of several parts and surgery on the wiring loom. Cost of components was just 700 euros but the swap required 20 hours of labor. The vehicle in question is an early model Leaf that was already fitted with an upgraded 40 kWh battery, and the owner desired an upgrade to CHAdeMO fast charging to better use the larger pack.

    Adding fastcharging to a base-model LEAF
    https://www.youtube.com/watch?v=1kyR5omOQu8

    Reply

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