| 1. Electricity Generation | Power-generation facilities | Electricity is produced from sources such as natural gas, nuclear power, hydroelectricity, wind, or solar energy. The generated electricity is supplied to the power grid. | Alternating current (AC); generator output voltage varies by facility and is increased for efficient transmission. | Generators, transformers, protection equipment, and grid-control systems | Maintains system frequency, voltage stability, and a balance between electricity supply and demand. |
| 2. High-Voltage Transmission | Transmission network | Transformers increase the voltage so electricity can travel long distances with lower current and reduced resistive losses. | Common transmission levels range from roughly 69 kV to above 500 kV, depending on the grid. | Step-up transformers, overhead lines, underground cables, circuit breakers, and substations | Protects the network from faults and isolates damaged sections when necessary. |
| 3. Local Distribution | Distribution substations and local power lines | Substations reduce transmission voltage to levels suitable for commercial, public, residential, or fleet charging installations. | Distribution voltage commonly ranges from several kilovolts to tens of kilovolts before final service transformation. | Substation transformers, feeders, switchgear, meters, and distribution lines | Controls the available electrical capacity and prevents overloads on local circuits. |
| 4. Site Service Entrance | Charging-site electrical room or service panel | Electricity enters the charging site through a utility connection. A service panel distributes power to individual charging circuits. | Low-voltage AC service; many installations use single-phase or three-phase power, depending on site capacity. | Service disconnect, switchboard, circuit breakers, energy meter, surge protection, and distribution panels | Provides overcurrent protection, emergency disconnection, grounding, and energy measurement. |
| 5. Charging-Station Connection | Charging station, also called electric vehicle supply equipment (EVSE) | The station connects the vehicle to the electrical supply and manages the charging session. For AC charging, the station primarily controls and safely delivers AC; it does not usually convert the power to DC. | AC charging commonly operates at approximately 3.7–22 kW, while DC charging can range from about 25 kW to more than 350 kW. | Charging cable, connector, contactors, communication controller, display, authentication system, and residual-current protection | Checks connection status, confirms vehicle readiness, controls energization, and stops power when a fault is detected. |
| 6. Vehicle Identification and Handshake | Between the charging station and the vehicle | The vehicle and station exchange information about connector status, charging limits, battery condition, and whether charging is permitted. | Charging current and voltage are not applied until the required safety conditions are satisfied. | Proximity detection, control-pilot circuit, communication controller, and vehicle charge-control system | Prevents the cable from being energized incorrectly and confirms that the connector is properly inserted. |
| 7. Power Conversion | Inside the vehicle or inside the charging station | During AC charging, the vehicle's onboard charger converts grid AC into controlled DC. During DC fast charging, the station performs the AC-to-DC conversion and sends DC directly to the battery system. | Battery-pack voltage commonly falls within roughly 250–ยี่? 900 V DC, depending on vehicle design and operating conditions. | Onboard charger for AC charging, or rectifier and DC power modules for DC charging | Regulates voltage and current while limiting temperature, power, and electrical stress. |
| 8. Battery Management and Cell Charging | Vehicle battery pack | DC power is distributed through the battery pack. The battery management system monitors individual cell groups and controls charging according to temperature, voltage, state of charge, and cell balance. | Lithium-ion packs generally use a controlled constant-current/constant-voltage charging profile. | Battery cells, modules, busbars, contactors, sensors, cooling system, and battery management system | Prevents overvoltage, excessive current, overheating, deep imbalance, and charging outside safe limits. |
| 9. Charging Profile and Power Reduction | Vehicle and charging-station control systems | Charging is usually fastest at a lower or moderate state of charge. As the battery approaches its upper voltage limit, the system reduces current to protect the cells and complete balancing. | Power typically decreases near high state of charge; the final portion can take disproportionately longer than the initial portion. | Battery management software, thermal sensors, current sensors, and charging-control software | Reduces heat generation and battery degradation while maintaining safe cell voltage limits. |
| 10. Energy Storage in the Battery | Electrochemical cells in the battery pack | Electrical energy is stored through reversible electrochemical reactions inside the battery cells. The pack stores energy as direct current for later use by the vehicle. | Usable battery capacity is measured in kilowatt-hours (kWh); charging energy is higher than stored energy because of conversion and thermal losses. | Positive electrodes, negative electrodes, electrolyte, separator, module housing, and thermal-management system | Maintains cell temperature and electrical limits to support performance, safety, and service life. |
| 11. Charging Completion | Charging station and vehicle control systems | The vehicle or station reduces current to zero when the requested charge level, battery limit, schedule, or safety condition is reached. The connector can then be released according to the system's procedures. | Charging current falls to 0 A before the power contacts are disconnected. | Contactors, locking mechanism, charging controller, user interface, and session meter | De-energizes the connector safely and records the delivered energy and session duration. |
| 12. Energy Losses and Efficiency | Grid connection, charging station, cable, onboard charger, and battery pack | Some input energy becomes heat because of resistance, power-conversion losses, battery chemistry, cooling requirements, and standby consumption. | Overall wall-to-battery efficiency is often approximately 80–95%, varying with charging power, temperature, battery condition, and equipment design. | Conductors, converters, transformers, cooling fans or pumps, contactors, and control electronics | Thermal management and controlled power delivery limit losses and help prevent overheating. |