Preface
BYD is a well-known new energy vehicle brand and a pioneer and leader in the global new energy vehicle industry. BYD's business layout covers electronics, automobiles, new energy and rail transit, and plays a pivotal role in these fields, from energy acquisition, storage, to application, to build a zero-emission new energy overall solution.
The charging head network summarizes the disassembled two BYD charging guns, both of which are on-board charging guns, supporting 8A charging current and 1760W power. One of the charging cables has a control box at the plug, while the other has a traditional design with a control box in the middle of the body. The following brings a summary of BYD's two charging guns to understand the internal design principles.
BYD 1760W AC charging gun for new energy vehicles
BYD's portable charging cable supports 8A current output and 1760W output power. This charging cable transfers a separate control box to the inside of the plug, making it more portable while still retaining important safety features, supporting AC overvoltage, undervoltage, charging overcurrent protection and leakage protection functions to ensure safe charging.
Through the dismantling of the charging head network, it was learned that the AC plug of this charging gun is large in size and contains detection and protection circuits inside. Two separate circuit boards are used inside the plug for protection detection and charge control. The input terminal of the circuit board of the charge control is welded with a varistor and a discharge tube for overvoltage protection, and two current transformers are used to detect the overcurrent and zero sequence current respectively, and the charge is controlled by two Hongfa relays.
The circuit board for protection detection uses a BYD automotive-grade MCU for parameter detection and protection control, Texas Instruments and Shengbonwe op amp for parameter acquisition, and Texas Instruments voltage regulator chip for power supply to the MCU and op amp. The charging control circuit board is equipped with a switching power supply circuit using an Infineon power supply chip. This charging gun uses automotive-grade devices and a wide temperature regulator chip to meet the normal use of a wide temperature range, and the internal components are glued and fixed to prevent damage caused by drops, and the overall design and materials are very reliable.
Related Reading:
1. Dismantling report: BYD 1760W new energy vehicle AC charging gun
BYD 1760W AC charging gun for electric vehicles
BYD's AC charging gun is about 5 meters long and has a rated power of 1760W. The end of the charging gun conforms to the design of the domestic electric vehicle charging port, so it can charge many electric vehicles on the market, and the versatility is good. The control box that comes with the product supports ground fault, over/undervoltage, over-temperature fault, leakage fault, and over-current fault prompts, and the charging status is clear at a glance, and users will feel at ease when using it.
By opening the control box, the charging head network found that the three wires of fire, zero and ground were fixed with screws, and two slightly thinner wires were additionally provided to achieve temperature monitoring. The internal PCB board is equipped with varistors, ceramic discharge tubes and other protection devices to achieve overvoltage and lightning protection. GigaDevice GD32E230C8T6 microcontroller is used to realize charging state parameter acquisition, function control and LED light drive, and an independent power supply board is used to reduce the voltage supply and SAMXON brand capacitors for filtering, and the overall material is reliable.
Related Reading:
1. Dismantling report: BYD 1760W electric vehicle AC charging gun
Summary of the charging head network
The charging gun is used to connect new energy vehicles to the power grid for charging, and provides comprehensive protection functions such as overvoltage, overcurrent and leakage for new energy vehicles to ensure the safety of personnel and vehicles. Both charging cables are about 5 meters long, and the control panel of one is set inside the plug, while the other uses a traditional control box design.
Both charging guns are equipped with complete protection circuits, using varistors and gas discharge tubes for lightning protection, zero-sequence current transformers for leakage protection, MCUs for voltage and current parameter detection, and relays to control the charging output. The internal materials of the charging gun are all first-line brands, and the workmanship and materials are solid to ensure the safe charging of new energy vehicles.