Preface
Aultite has launched a new national standard electric bicycle charger, which adopts PFC+LLC+SR high-efficiency architecture design, compared with traditional electric vehicle chargers, there is no need for cooling fans. With the blessing of high-efficiency architecture, it is not only more efficient, but also smaller in size, which is easy to carry and store in daily life, and the user experience is also better.
This EV charger has an output power of 218.4W, an output specification of 54.6V 4A, and supports charging 13 strings of lithium batteries. The charger adopts a pinzi socket, which can replace the power cord of different lengths according to different usage scenarios, and comes with a 1.2-meter-long output cord with a new national standard plug. The following charging head network will bring the charger of this electric bicycle, and take a look at the internal materials and design.
Appearance of Aolet 218.4W electric bike charger
The body of the 218.4W electric bicycle charger is designed with an integrated design with the output line, the body is a neat straight plate shape, and the shell is made of PC flame retardant and fireproof material, and the surface is frosted.
The fuselage and power cord are split design, because it supports a wide range of 100-240V voltage input, so the application scenarios can be broadened by replacing different specifications of power cords, which has a natural advantage in adapting to regions.
There is an indicator light at the corner of one end of the top surface of the fuselage, which can give users intuitive feedback on whether the charging status is normal or not, and ensure the safety of charging.
There is a charger nameplate on the bottom of the fuselage, printed with product parameters and certification and other relevant information.
The charger model is AP-PN240CH05460040, supports 100-240V~50/60Hz 5A input, supports 54.6V4A output, and the output power is 218.4W.
The products have passed CCC, CE, FCC, UL, UKCA, GS and other safety certifications, and the quality is guaranteed.
In addition, there are protrusions at the bottom four ends of the fuselage to effectively prevent the nameplate from wearing.
The cable at the output end has been treated with anti-bending.
In addition, the terminal housing has a protruding design for easy plugging and unplugging.
The plug specification is the new national standard for electric bicycles, and the positive electrode adopts an independent cavity design, which can eliminate the potential safety hazards caused by mismatch and greatly improve the charging safety.
The measured length of the charger body is 187.99mm.
The width is 77.32mm.
The thickness is 40.8mm.
The length of the output cable is about 124cm.
The size of the charger body in the hand is intuitively felt.
In addition, the weight of the product was measured to be about 691g.
Aolet 218.4W electric bike charger disassembly
After reading the unboxing of this charger, let's disassemble it and take a look at the internal scheme and materials.
First, along the seam of the charger shell, pry open the charger shell and take out the internal PCBA module.
Close-up of the light guide post inside the housing for charger charge status indication.
The PCBA module is wrapped with a heat sink as a whole and fixed by soldering.
The AC input is directly soldered to the PCBA module with wires.
The output wires are also soldered.
Cut the connecting wires and take out the PCBA module.
The input wire is connected by welding, and the solder joint is insulated with heat shrinkable tube.
The PCBA module wraps the heat sink for heat dissipation, and the heat sink is fixed by a buckle.
The length of the PCBA module is about 174mm measured by vernier calipers.
The width of the PCBA module is about 71.4mm.
The thickness of the PCBA module is about 36.2mm.
Remove the heat sink wrapped by the PCBA module, and set a black Mylar sheet insulation inside the heat sink.
A long heat sink is fixed on the side of the PCBA module to dissipate heat from the rectifier bridge and PFC rectifier tube, and the position of the corresponding secondary side is wound with tape insulation.
The left heat sink is a synchronous rectifier tube for heat dissipation, and the right heat sink is a PFC switch tube for heat dissipation.
The front of the PCBA module is at a glance, the right side is the AC input terminal, soldered blue Y capacitor, safety X2 capacitor, common mode inductance. Weld the thin-film filter capacitor and filter inductor to the right, weld the PFC boost inductor below, and weld the PFC switch tube on the left. Below the PFC switch heat sink is a high-voltage filter capacitor.
The left side of the high-voltage filter capacitor is the switching transformer, the lower part of the transformer is the synchronous rectifier tube, and the left side is the output filter capacitor, the filter inductor and the relay that controls the output.
The back of the PCBA module is welded with a 2-in-1 controller, LLC switch tube, feedback optocoupler, synchronous rectifier controller, op amp and voltage regulator chip.
List of PCBA module inputs, soldered blue Y capacitors and blue varistors, and common mode inductors are insulated with plastic sheets.
The input fuse specification is 5A 250V.
VDR14D561K varistors are used for surge protection.
The safety X2 capacitor is from Dongguan Yideng Electronics, and the specification is 0.47μF.
The two common mode inductors are wound with copper tape and the bottom is welded with an insulating bracket.
The other safety X2 capacitor is from Shenzhen Shanrui Electronics, with a specification of 0.68μF.
There is a heat sink on the side of the PCBA module.
The rectifier bridge and PFC rectifier tube are fixed to the heat sink using screws.
The rectifier bridge is from Zhirun, the model is GBU1510, and the specification is 15A 1000V.
The two thin-film filter capacitors are from JURCC and are 1μF500V and 0.68μF500V, respectively.
The filter inductor is made of yellow magnetic surrounding.
The primary PWM main control chip of the charger adopts NXP TEA2016AAT, one chip has a built-in LLC controller and PFC controller, built-in digital architecture control, simplifying the design while reducing the number of peripheral components, and the chip has multiple built-in perfect protection functions, with a very high degree of integration.
The filter capacitor that supplies power to the main control chip comes from Fuzhiqing, and the specification is 47μF50V.
The PFC switch tube is screwed to the heat sink.
The PFC switch is from Longteng, model LSD55R140GF, superjunction NMOS, withstand voltage 550V, conduction resistance 140mΩ, and adopts TO220MF insulated package.
Two 50mΩ resistors are connected in parallel to detect the PFC switch current.
PFC boost inductors are tightly wound and insulated with adhesive tape.
The PFC rectifier tube is from Ween, model BYC15-600P, specification is 600V 15A, and it is packaged in TO220AC.
Between the two heat sinks are the high-voltage filter capacitors and the transformer.
The high-voltage filter capacitor is from Emerald and is specified at 450V to 180μF.
The ES5J diode is used for PFC circuit bypass to charge high-voltage electrolytic capacitors at start-up.
NTC thermistors are used to suppress inrush currents for high-voltage capacitor charging.
The LLC switch is from Wei'an, model WMO26N65F2, superjunction NMOS tube, withstand voltage 700V, conduction resistance 170mΩ, and TO252 package.
The resonant capacitor is from Jiewei and has a specification of 0.047μF1KV.
The transformer is marked with 48V5A specification.
Two Orient OR 1008 optocouplers are used for output voltage feedback and protection control.
The output side is welded with a blue Y capacitor, a filter capacitor, a filter inductor and a relay, and a switch tube heat sink behind it.
The output synchronous rectifier chip is from MPS, model MP6924A, is an LLC synchronous rectifier controller, MP6924A integrates two synchronous rectifier controllers, which are used for the rectification application of LLC two secondary coil outputs, and is suitable for LLC converter synchronous rectification application. It can save one controller, simplify the secondary circuit design, and has stronger anti-interference and fast shutdown functions, and can be compatible with CCM/DCM mode. At the same time, it supports a wide range of 4.2-35V working voltage, which can be applied to USB PD3.1 fast charging 140W power supply design.
The two synchronous rectifiers are screwed to the heat sink and are provided with thermal pads and insulating particles.
The two synchronous rectifier tubes are from Huarui Micro, model HRG150N13P, NMOS, withstand voltage 150V, conduction resistance 11mΩ, and TO220 package.
The two output filter capacitors are from Man Yue and are specified at 470μF 63V.
The filter inductor is made of magnetic surrounding, and the bottom is insulated with bakelite board.
Two 20mΩ resistors are connected in parallel to detect the output current.
A 15A chip fuse is used for output overcurrent protection.
The filter capacitor is from Fuzhiqing, and the specification is 470μF35V.
The voltage regulator chip is from Changjing Technology, the model is CJ78M12, it is a three-terminal voltage regulator chip with 12V output voltage, the highest input voltage is 35V, the output voltage is 12V, and the output current is 0.5A, and it is packaged in TO252.
The dual op amp from Blum Electronics, model LM358S, is a universal double op amp.
The transistor is also from Blum Electronics.
SMD LEDs are used to indicate the charging status.
The relay used for output control is from Zhongtong, model ZT601, and the coil voltage is 12V.
The PCBA module is supported by a rubber block.
Close-up of a black supporting rubber block.
Close-up of eight blue Y capacitors, from Dongguan Yideng Electronics.
A list of all dismantling and a family photo.
Summary of the dismantling of the charging head network
This electric bike charger is dedicated to lithium batteries and supports charging 13 strings of batteries. The charger adopts a pinzi socket and is equipped with a 1.2-meter long output cable, and can also be replaced with different lengths of power cords according to different usage scenarios to meet application needs. The charger adopts the high-efficiency PFC+LLC+SR architecture, which greatly improves the efficiency compared with the traditional EV charger, not only removes the cooling fan, but also greatly reduces the volume, and further improves the consumer experience.
Through dismantling, the charging head network learned that the PCBA module inside the electric bicycle charger of Aulite is wrapped with an aluminum alloy heat sink as a whole to enhance the heat dissipation performance. The charger has a built-in NXP TEA2016AAT 2-in-1 controller, the PFC switch is from Longteng, the LLC switch is from Wei'an, and the synchronous rectifier is from Huarui Micro. The internal high-voltage filter capacitor comes from Emerald, and the output filter capacitor comes from Wanyu, and the internal materials and workmanship of the charger are very reliable.