**Detailed Explanation of New Energy Vehicle Charger**
Car chargers are a vital component in new energy vehicles, and their market has grown rapidly alongside the expansion of the electric vehicle industry. In 2016, the market size for on-board vehicle chargers was approximately 2 billion yuan. With the increasing production of new energy vehicles, it is estimated that by 2020, the domestic market for electric vehicle on-board chargers will reach 7.7 billion yuan.
Compared to traditional vehicles, new energy vehicles have three core components: the battery assembly (battery and battery management system), the motor assembly (motor and motor controller), and the high-voltage "electric control" assembly, which includes the on-board DC/DC converter, on-board charger, electric air conditioner, PTC, and high-voltage power distribution box. Among these, the on-board DC/DC converter and on-board charger are the most essential parts.
*Figure 1: Schematic diagram of the structure of the new energy vehicle system*
**Key Parameters of the Car Charger:**
1. Input voltage: AC 220V ±10%, 50–60Hz
2. Output voltage: 48V, 72V, 144V, 200–420V, 500–650V
3. Output current: 30A, 25A, 20A, 10A, 50A
4. Output power: 1.8kW, 3kW, 3.3kW, 30kW
5. Output ripple: ≤1% (full load)
6. Voltage and current stability accuracy: ≤1%
7. Harmonic distortion: ≤5%
8. Working efficiency: ≥95%
9. Working status: supports long-term operation and single charging
10. Protection functions: overvoltage, overcurrent, overheating, short circuit, and reverse polarity protection
11. Low-voltage auxiliary power supply: DC 13.5V/100W regulated power supply
12. CAN communication interface
13. Safety indicators: insulation resistance ≥200MΩ, withstands 1500V/min
14. Power factor: 0.99 (with active power factor correction - APFC)
15. Size: varies depending on model
**Key Features of the Car Charger:**
1. Supports high-speed CAN network and BMS communication to check battery connection status and obtain real-time data from the battery system before and during charging.
2. Can communicate with the vehicle monitoring system via the high-speed CAN network, sending working status, parameters, and fault alarms, while also accepting start or stop charging commands.
3. Comprehensive safety protection features include:
- AC input overvoltage protection
- AC input undervoltage alarm
- AC input overcurrent protection
- DC output overcurrent protection
- DC output short-circuit protection
- Output soft start function to prevent current surges
- Temperature, voltage, and current monitoring during charging
- Single battery voltage limiting function based on BMS data
- Automatic detection of proper connection between charger, charging post, and battery
- Charging interlock function to prevent vehicle start until the charger is connected
- High-voltage interlock function to lock output if dangerous high voltage is detected
- Flame retardant design
As a power electronics system, the car charger consists mainly of a power circuit and a control circuit. The power circuit typically includes a DC/DC converter made up of a transformer and power transistors. The control circuit, centered around a controller, enables communication with the BMS and controls the power circuit according to the three-stage charging curve.
When the charger connects to the AC source, it does not immediately send energy to the battery. Instead, the BMS first collects and analyzes the battery’s condition, then adjusts the charging parameters accordingly. The charger comprises two main parts: the power supply section (main circuit) and the control board. The control board manages, monitors, measures, calculates, corrects, protects, and communicates with external systems, acting as the “central brain†of the charger.
The power supply section converts 220 VAC into 300 VDC. It is divided into two parts: PFC (Power Factor Correction) and LLC (a type of resonant converter). In essence, PFC handles AC to DC conversion, while LLC manages DC to DC conversion.
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