Electric Vehicle Charger - Taking the Fleet to the Next Level

The Problem Statement

Promoting the 2030 mission of all electric vehicle fleet in order to slash down the fuel import bill & running cost of vehicles, the client wanted to make inroads in the electric vehicle space by building an electric vehicle charger. The client turned to KritiKal Solutions to build a high-efficiency lead-acid battery charger which would be packed with a variety of features like temperature sensing circuit, LED indication, cooling system, protections for output overload, input inrush, etc.

Screenshots

The Solution

KritiKal built a design for 800W (65VDC, 12.3A) Lead-Acid battery charger for electric vehicles & developed it on TI controller chip. The charging system is compatible with varied voltage supply in different areas.

There are 2 versions of the charger- PFC controller based charger & non-PFC controller based charger. For PFC based charging- the input power supply should be in the range of 90V-300V. For non-PFC controller based charger- the input supply should be 170VAC-300VAC along with 47Hz-63Hz input frequency range and the output maximum voltage should be 65VDC +/- 0.50V.

This model has the capability of charging lead acid battery up to 65V, with up to 12A
Involves temperature sensing circuit & protection features like output overload protection, short-circuit protection, over temperature protection, output over voltage protection, output reverse polarity protection, input inrush protection, & input over-current protection
Works on full bridge phase shifted PWM topology
Red LED which indicates Charger Input Supply
4 Green LEDs indicate the continuous charging status
Built-in cooling fan to maintain even temperature throughout
Trickling charge functionality to avoid discharge in case of auto cutoff protection when it reaches 100%
Follows EMI/EMC compliances

Benefits Delivered

KritiKal with its expertise in Embedded Systems built a high voltage & highly efficient charger that supports a universal voltage range. As there is always a gap in the manufacturing warranty of a Chinese product in the Indian market, our electric vehicle charger helped the client to overhaul this market gap by offering assured warranty of the product. Also, our path-breaking work helped the client distribute the product to vendors at a fast pace which in turn promotes make in India initiative taken by our Government.