2 kW Smart Battery Charger for 48 V & 72 V EV Packs
in development.
Under development — specifications are design targets. Image shown is a design render, not a photo.
A high-efficiency 2 kW on-board or off-board charger for electric two- and three-wheelers and light EVs. It runs from any single-phase mains supply between 120 and 264 Vac and charges 48 V or 72 V lithium packs — two build variants on the same circuit board. A two-phase interleaved PFC stage draws clean, near-sinusoidal current from the mains, and a resonant LLC converter with synchronous rectification delivers the output with soft switching for high efficiency and low EMI. Two digital signal controllers run the complete power and charge control in firmware. The charger talks to the battery management system over CAN to set the charge profile, chemistry and limits, and reports status to a phone app over Bluetooth.
What it does.
- 2 kW output from 180–264 Vac; automatic derating to 1.3 kW at 120 Vac
- Universal single-phase input 120–264 Vac, 50 / 60 Hz, with active power-factor correction
- Two build variants on one PCB: 48 V (16S LFP, 40–58.8 V, up to 40 A) and 72 V (24S LFP, 60–100.8 V)
- LFP and NMC chemistries, selected by the battery management system over CAN; LFP profile by default
- Pre-charge, constant-current, constant-power and constant-voltage charging with automatic termination
- Battery voltage window check — refuses to charge the wrong pack or wrong variant
- Interleaved PFC and soft-switching resonant LLC with synchronous rectification; efficiency target ≥ 94 % at 230 Vac
- Adaptive DC bus voltage to keep the resonant converter at its most efficient operating point
- CAN / CAN-FD link to the BMS; Bluetooth LE for a phone app; service UART for diagnostics and updates
- Front panel with mains/PFC OK, fault and a four-step battery-charge bar
- Full protection: input fuse and surge, inrush limiting, bus over / under-voltage, cycle-by-cycle over-current, output over-voltage and short-circuit, reverse battery, over-temperature and fan failure
- Reinforced isolation between mains and battery; forced-air cooling with dedicated primary and secondary heatsinks
Electronics first.
System thinking throughout.
Two-phase interleaved power-factor correction · half-bridge resonant LLC converter · synchronous rectification · fully digital control · CAN link to the BMS · Bluetooth LE and service UART · forced-air cooling
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