Preface
The two new national standard electric vehicle chargers launched by Fuyuan Electric have been obtained by the charging head network. Both chargers are equipped with a wide voltage input of 100-240V, allowing users to use it with peace of mind in different voltage environments. One of them outputs 42V4A, which is suitable for charging 10 strings of lithium batteries, and the other outputs 54.6V3A, which is suitable for charging 13 strings of lithium batteries. Using the Pin word power cord as input, you can change the power cord of different lengths according to your needs to adapt to different scenarios.
The new national standard plug cable is the output cable of these two chargers, with a length of 1.2 meters. The charger shell is sealed with IP67 protection and V0 fire rating, providing users with a safer charging experience. The high-efficiency PFC+LLC+SR architecture and gallium nitride power devices improve energy efficiency and support fast charging of e-bikes, allowing users to complete the charge in a short time and continue to use e-bikes.
Compared with traditional EV chargers, this charger is not only more efficient, but also abandons the cooling fan design, and is smaller in size, improving the user's charging experience. There is no need for a cooling fan, and the small size makes it more convenient for users to carry and use it on a daily basis.
Fuyuan Electric 168W new national standard electric bicycle charger appearance
The two chargers of 42V4A and 54.6V3A specifications launched by Fuyuan Electric are equipped with double-foot plug power cords and output cables of new national standard terminals.
The body of this charger adopts Fuyuandian's exclusive one-piece waterproof light sheet appearance patent shell, and the surface is frosted and anti-fingerprint. Charging is complete or not connected, the indicator light is green.
The bottom of the fuselage is printed with the charger specification information.
The bottom nameplate information includes charger parameters, indicator status introduction, precautions, and business information.
Close-up of the nameplate at the bottom of the fuselage
型号:FY1694204000
输入:100-240V~50/60Hz 2.5A
Output: 42V4A
Degree of protection: IP67
Manufacturer: Shenzhen Fuyuan Electric Power Supply Co., Ltd
The product has passed CQC certification and meets the GB 42296-2022 specification.
An indicator light on the top of the fuselage, where a red light indicates charging, and a green light indicates that charging has been completed or is not connected.
The input power cord adopts the national standard double-pin plug, which is designed to be easy to plug and unplug.
The connections between the cables at both ends of the fuselage and the fuselage are designed to resist bending and bending.
Close-up of the new national standard terminal of the output cable, and the independent cavity design of the positive electrode can eliminate the potential safety hazards caused by mismatch and greatly improve the charging safety.
The measured length of the charger body is 149.56mm.
The body width is 64.3mm.
The thickness is 37.9mm.
The length of the output cable of the new national standard is measured to be about 1.2 meters.
In addition, the total weight of the charger was measured to be about 527g.
Fuyuan Electric 168W new national standard electric bicycle charger dismantling
After reading the appearance of Fuyuandian's new national standard electric bicycle charger, let's disassemble it and take a look at the internal design and materials.
First, the charger shell is disassembled along the seam of the shell, and the internal PCBA module is wrapped with aluminum sheets for heat dissipation.
The PCBA module is fixed by snapping.
Remove the heat sink fixed by the buckle, and the internal PCBA module is insulated with black Mylar sheets.
The PCBA module is insulated by Mylar sheets.
The PCBA module is removed from the inside of the Mylar sheet, and a thermal pad is also pasted inside to enhance the heat dissipation performance.
The length of the PCBA module measured by vernier calipers is about 132.3mm.
The width of the PCBA module is about 52mm.
The thickness of the PCBA module is about 26.9mm.
The input end of the PCBA module is connected by wire soldering.
The varistor is from Hongzhi, model 14D561K, and is used for input surge overvoltage protection.
NTC thermistor silkscreen 1.3D13 for suppressing inrush current at power-up.
The common mode inductor is magnetically surrounded, and the inside is insulated by a bakelite board.
The rectifier bridge is fixed to the heat sink using screws.
The rectifier bridge is from Wald.
Close-up of thin-film filter capacitors and filter inductors.
The thin-film filter capacitor is from Jiewei, which is the MPP85-BOX series, and the specification is 1μF450V.
The filter inductor is magnetically wrapped.
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 two filter capacitors that supply power to the main control chip are 100μF 50V.
The PFC switch uses a 650V enhanced GaN power device with a 240mΩ conduction resistance. The device is ESD-protected on all pins, and the switching speed can be adjusted by a resistor in the gate path. The device has reverse conduction capability, no reverse recovery losses, and supports high-frequency switching.
Trouco's technology-enhanced GaN power devices feature low-voltage insulated thermal pads connected by a current-sensing resistor for better heat dissipation. Supports totem pole PFC, half-bridge/full-bridge LLC applications, mobile phone fast charging, laptop power supplies, LED lighting power supplies, motor drives, server and inverter applications. The device is available in a 5*7*0.8mm QFN package to save board space.
The 45mΩ sampling resistor is used to sense the PFC switch current.
The PFC boost inductor is wound with a PQ2620 core.
The PFC rectifier tube is a silicon carbide diode MSM06065G1 with 650V withstand voltage and 150°C continuous forward current of 6A, which is DFN5*6 package, ultra-thin package saves volume, and is suitable for high-power GaN fast charging applications with high power density.
The high-voltage capacitor comes from Chuanghui Electronics.
The specification is 100μF 450V.
The LLC switch is from MPSEN, model SLL65R380E7, NMOS, withstand voltage 650V, conduction resistance 318mΩ, and DFN8*8 package.
The resonant inductor is insulated with tape.
The resonant capacitor is from Jiewei, which is the MPP92-BOX series, with a specification of 0.015μF1KV.
The transformer is made of PQ3220 magnetic core wound and tightly wound tape insulation.
Two blue Y capacitors are glued and reinforced.
Orient OR1009 optocoupler is used for output voltage feedback and PFC control.
The synchronous rectifier controller is from MPS, model MP6924A, is an LLC synchronous rectifier controller, with stronger anti-interference and fast shutdown function, and can be compatible with CCM/DCM mode. The MP6924A integrates two synchronous rectification controllers, which are used for the rectification application of the two secondary coil outputs of the LLC, which is suitable for the synchronous rectification application of the LLC converter.
Close-up of synchronous rectifier tube and filter capacitor.
The synchronous rectifier tube is from Hengtaike, model HGP195N15S, NMOS, withstand voltage 150V, conduction resistance 16.3mΩ, TO220 package.
The two output filter capacitors are from Chuanghui Electronics.
The specification is 330μF 63V.
Close-up of magnetic ring filter inductor.
The control board is soldered on the side of the PCBA module, and the MCU and other components are arranged on the control board.
The MCU comes from China Micro Semiconductor, model SC8F2892B, is an enhanced flash memory 8-bit microcontroller, built-in SPI communication module, I2C communication module, USART communication module, built-in 12-bit high-precision ADC and op amp. It mainly implements the communication protocol specified in GB 42296-2022 "Safety Technical Requirements for Chargers for Electric Bicycles" to ensure the safety and reliability of the charging process.
The 78L05 regulator is used to power the MCU.
The output is equipped with a filter capacitor, an adjustable resistor and an LED indicator.
Close-up of precision multiturn adjustable resistor with a resistance value of 1KΩ. Realize the output voltage trimming function.
Two-color LEDs are used to indicate the state of charge.
Youshun UTC358 dual op amps are used for feedback control.
A 20mΩ resistor is used to sense the output current.
The output VBUS switch is from Hengtaike, model HGN195N15S, NMOS, withstand voltage 150V, conduction resistance 17mΩ, DFN5*6 package.
The other VBUS switch model HGN080N10A, NMOS, withstand voltage 100V, conduction resistance 6.8mΩ, and adopts DFN5*6 package.
Summary of the dismantling of the charging head network
With an output power of 168W, Fuyuan e-bike charger is specially designed for lithium batteries and supports the charging needs of 10-string and 13-string batteries. The charger is equipped with a 1.2-meter long output cable that complies with the new national standard and uses high-quality materials and components.
After the dismantling and analysis of the charging head network, it was found that the PCBA module wrapped by aluminum alloy heat sink was used inside the Fuyuan electric bicycle charger, and the Mylar sheet insulation was used around the PCBA module, and the thermal pad was pasted at the position of the heating device, which effectively improved the heat dissipation performance. In addition, NXP's TEA2016AAT 2-in-1 controller is used inside the charger, and it is equipped with an enhanced gallium nitride device with a conduction resistance of 240mR for PFC switch, and a silicon carbide diode MSM06065G1 by MPSEN for PFC rectification.
In the LLC half-bridge circuit, two SLL65R380E7 switches with a conductive resistance of 318mR are used, combining the synchronous rectifier chip Xinyuan semiconductor MP6924A and Hengtaike MOS transistors. In order to effectively reduce the temperature of the internal components, a thermal pad is used to dissipate heat to ensure that the internal temperature is not too high. The adoption of the third generation of semiconductor GaN devices further improves the conversion efficiency, eliminating the need for additional fan cooling, while also significantly reducing the size to provide users with a better charging experience.
The output end of the charger is equipped with a control board, and adopts a micro-semiconductor SC8F2892B MCU, which conforms to the communication protocol and product reliability function specified in the "Safety Technical Requirements for Chargers for Electric Bicycles" to ensure the safety and reliability of the charging process. In addition, the internal electrolytic capacitor of the charger comes from Chuanghui Electronics, the film capacitor comes from Jiewei, and the input terminal is also set with a varistor for lightning surge protection to ensure the reliable and stable quality of the internal engineering.