Customized 72V 20A charger drawing
We have fully addressed the inefficiencies and unauthorized overvoltage issues associated with traditional battery charging systems. The unsafe and unauthorized use of 3-phase high-voltage electric cables poses significant accident risks, often leading to unwanted casualties. In Bangladesh alone, traditional 3-phase charging systems consume vast amounts of electricity to support approximately 4 million Electric Three-Wheelers (e.g., Easy Bikes).
We have developed an innovative, cost-effective product that benefits both people and the environment. This solution is centered on the advanced engineering, formulation, and configuration of a 72V 20A fast charger integrated with a hi-tech charging management system and enhanced/sophisticated circuitry. Our submission highlights the key technical innovations and unique features of the 72V 20A fast charger system. We believe this invention will make a significant contribution to the safe and efficient charging of Lithium-NMC batteries, tailored for electric vehicle technology, and aimed at reducing environmental impact. The charger is designed with overvoltage and under voltage risk minimization and is customized for use with Bangladesh’s electricity system, allowing it to operate efficiently on a residential 180-220V two-phase electric connection, thereby reducing electricity consumption. After collaborating with manufacturers, we ensured that our vision was brought to life in a way that aligns with our original thinking. The product is not only effective and affordable, but it also boasts a low charging and operating cost, making it accessible to the general population. Its durability ensures long-term use, providing value to users while maintaining affordability. This innovation offers a practical solution that improves everyday life while being economically sustainable.
- A newly configured, formulated, and customized 72V 20A fast charger system integrated with a high-tech charging management system and sophisticated circuitry. The system is specifically engineered for Lithium-NMC batteries with an integrated Battery Management System (BMS), designed for Electric Vehicles (EVs).
(b) A specially designed 72V 20A fast charger system featuring low charging costs and a universal two-phase charging system.
After researching these environmental and operational risks issues, including the high electricity consumption during charging, we designed and developed a long-lasting, auto cooling and environments friendly 72V 20A fast charger system. This advanced 72V 20A fast charger system is designed with high-quality low-high voltage control integrated with a customized Battery Management System (BMS) for optimal performance across various environments, including extreme temperatures and rough road conditions. The charger is designed with overvoltage and under voltage risk minimization and is customized for use with Bangladesh’s electricity system, allowing it to operate efficiently on a residential 180-220V two-phase electric connection, thereby reducing electricity consumption. Our submission highlights the key technical innovations and unique features of the 72V 20A fast charger system but also play a crucial role in boosting the income of low-wage earners, thereby contributing to economic growth in low-income communities. One of the key benefits of our 72V 20A fast charger technology is its cost-effectiveness. With a maximum charging cost of just Tk. 20-30 (Approx. 2-3 unit of electricity require), of 48V108Ah & 60V160Ah Lithium NMC Batteries per charge cycle.
This results in an incredibly low running cost of only Tk. 0.12 per kilometer for Three Wheelers, making it an affordable and efficient solution for everyday transportation.
The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:-
The 72V 20A fast charger is customized designed for efficient charging of particularly for Lithium NMC batteries for Electric Vehicles (EV) only, specifically the 60V160Ah model. Below are the key specifications of the charger:
General Specifications:
Input Voltage Range : 180V-220V AC (Single or Two-Phase)
Output Voltage : 72V20A (Selectable based on the battery pack)
Output Current : 20A (Max). Charging Time: 5-6 hours for a full charge (for a 60V160Ah battery)
Charging Type : Constant Current (CC) and Constant Voltage (CV) Efficiency : ≥ 90%
Power Consumption : Less than 2 units of electricity for a 100% charge (for the 60V160Ah battery)
Cable Type : 2-phase connection compatible with standard electrical lines
Mechanical Specifications:
Size : Compact and lightweight, designed for portability
Weight : 2 KG
Enclosure : Durable, weatherproof casing. Auto cooling system to prevent overheating
Plug Type : Standard Anderson plug for easy use with two pins socket
Safety Features:
Overvoltage Protection : Protects the battery from excessive voltage
Overcurrent Protection : Limits the current to prevent overheating and overcharging
Short Circuit Protection : Prevents electrical hazards due to short circuits
Temperature Control : Automatic cooling system that activates as needed
Automatic Shut-off : Charger stops when the battery is fully charged
Additional Features:
User-Friendly : Plug-and-charge design with simple operation
Portability : Lightweight and easily carried, allowing charging at any place with a 2-phase household electric line
Durability : Built to withstand varying environmental conditions, suitable for both home and on-roadsides use. This charger is specifically designed to minimize charging costs, ensure battery health, and provide a reliable, risk-free solution for EVs.
Compariosn Specifications
Newly Configured, Formulated & Customized engineered, low charging cost, 72V 20A Charger: (For Lithium NMC Battery only)
When comparing single-phase and 3-phase EV chargers, it’s essential to understand the key differences in their functionality, efficiency, and applicability. Here’s a detailed comparison:
| SL No. | Parameter | Description | |
| Single-Phase EV Charger | 3-Phase EV Charger | ||
| 01 | Power Supply and Phases | Power Supply: Utilizes two live wires from a standard residential supply, which is typically found in most homes.Voltage: Usually operates on a 180-220V power supply.Common Use: Suitable for residential and small commercial setups where only single-phase power (or split-phase) is available. | Power Supply: Utilizes three live wires, typically available in industrial or commercial environments.Voltage: Operates on a 400-440V power supply.Common Use: Primarily used in industrial or commercial settings with 3-phase power availability, allowing for more efficient energy distribution. |
| 02 | Charging Speed | Charging Speed: Generally slower than 3-phase chargers due to lower power delivery. It’s suitable for overnight charging or situations where time isn’t a constraint.Example: The Lithium NMC battery in your EVs can be charged in about 5-6 hours using a single-phase charger. | Charging Speed: Significantly faster charging due to higher power availability, reducing charging time considerably.Example: Can fully charge large EV batteries in a few hours or even less, depending on the vehicle and battery capacity but charging costs are higher. |
| 03 | Installation and Infrastructure | Installation: Easier and cheaper to install in residential areas where only single-phase power is available.Infrastructure: Does not require extensive upgrades or changes to existing residential electrical infrastructure. | Installation: More complex and expensive to install, often requiring upgrades to existing electrical systems or specific infrastructure.Infrastructure: Requires 3-phase power supply, which is generally available in commercial or industrial areas, not common in residential settings. |
| 04 | Cost | Initial Cost: Typically lower due to the simpler technology and easier installation process. | Initial Cost: Higher due to the need for specialized equipment and potentially complex installation. |
| 05 | Applications | Ideal for personal use in homes or small businesses.Suitable for smaller EVs or those with lower energy requirements. | Best for commercial use in places like EV charging stations, or industrial environments where quick turnaround on charging is needed.Suitable for larger EVs with bigger battery packs or fleets of vehicles that need rapid, high-capacity charging. |
Conclusion
single-phase Chargers are perfect for residential settings or areas without access to 3-phase power, offering a good balance between costs and charging time for typical daily use.
3-Phase Chargers are better suited for commercial or industrial settings where faster charging is necessary, and where the infrastructure supports higher voltage and current supply but it will cause higher cost for EV Three Wheeler.
Charging problems solved and affordable technology formulated:
For our specific application with EVs, the single-phase charger provides an affordable and accessible option that fits well with the evolving needs of our electric vehicles, especially given the context of the Bangladesh market. There are no specific charging stations for EVs; instead, we have developed an easy-to-use charging system that is both user-friendly and cost-effective.
We have customized and upgraded the 48V/60V 20A lightweight portable charger to support a 60V160Ah Lithium-ion battery, with a charging time of 5-6 hours. This charger operates on a two-phase voltage of 180-220V and is designed to reduce charging costs. Our innovative technology facilitates easy charging with any two-phase cable, allowing users to plug in and charge anywhere with minimal costs. The portable charger also features a risk-free auto-cooling system and consumes 2-3 units of electricity for a full charge.
