How the brief was fulfilled

Existing chargers reviewed had usability issues around installation – the enclosure needed to be disassembled to install, with components in both halves which needed three hands or to be disconnected. As their first smart charger, there were multiple additional components to be integrated, including switches and relays which would not be defined during the design process.
The design intent from the start was to design a product for multiple users – specifier, installer and end user, that would meet all of their requirements.

Sustainable Design

The key outcome from meetings around product use and specification was that the enclosure would remain sealed during installation. A cover ring was used which when removed, gave multiple wall fixing points around the perimeter of the sealed charger, allowing it to be held against the wall and drilled directly to the wall. The main AC input was also carefully considered, with a secondary sealed compartment allowing access to wire the charger while keeping the main enclosure sealed.

Future requirements for smart charging were taken care of by including a DIN rail within the product. Most of the devices that will need to be fitted, but have not yet been specified, have versions that fit to a DIN rail and conform to the DIN standard. By including an area in the charger behind a sealed door, additional relays, switches, counters can easily be fitted when required, and the charger updated when standards in EV smart charging are confirmed.

The material choice is critical in an EV charger, which is located outdoors in temperatures from -30 to +40, and a harsh environment where cables and connectors are constantly striking the enclosure. The material sourced stays tough under the coldest temperatures and meets the maximum requirement for flame retardancy and UV resistance. This material has properties which are not ideal to produce a uniform surface finish, so the texture was carefully chosen to maintain the look of the charger over an estimated life in service of ten years.