Geely car owners can rest assured to buy, Geely 2kW portable DC charger dismantling, this workmanship is absolutely amazing

Preface

The charging head network purchased the DC charger of Geely Panda mini electric vehicle, which is a portable design, with a total weight of 4.8Kg, and the length of the input line of the charger is about 2.9 meters, and the length of the output line is about 1.5 meters, which can meet the daily charging needs. The charger supports 175-265Vac input, the output voltage is 250-500VDC, and the maximum output current is 5.5A.

Geely's charger is equipped with two cooling fans to speed up air circulation and blow heat out, which can be used for long-term charging. The charger supports IP66 protection level, which has a certain protection ability when charging outdoors. Let's bring a dismantling of Geely's 2kW portable DC charger, and take a look at the internal materials and workmanship.

Geely 2kW portable DC charger unboxing

The product is shipped in a kraft paper box, with the Geely Automobile brand logo, product name and model printed on the front.

The package contains a Geely 2kW portable DC charger and an instruction manual.

Geely's 2kW portable DC charger consists of three parts: a connecting cable, a charger and a gun head. There is a clear difference in the thickness of the two parts of the cable, which is different from the common AC charging guns on the market.

The input power cord adopts a three-pin plug, and the two sides are concave to facilitate user plugging and unplugging.

The charger adopts a plastic shell made of PC fireproof material, which is available in black, white and silver gray colors. The top shell is not only sprayed with silver-gray metallic paint to enhance the texture, but also has a curved design on both sides to make the whole more designed.

The top cover is equipped with a teardrop-shaped cut-out area and a circular groove.

The droplet-shaped area is equipped with a power-on switch and a ring indicator, which will light up green when the power is on normally.

The round groove is affixed with a GEELY brand medallion.

There are windows on both sides of the input terminal of the fuselage, and there are two cooling fans inside.

There is an air outlet window at the other end.

Both ends of the cable are designed for enhanced protection.

There is a yellow warning label on the side, indicating that the machine will wait for 5 minutes after the power is off.

The bottom of the fuselage is pasted with a non-slip mat and a product nameplate.

Close-up of the product nameplate

Product Name: 2kW Portable DC Charger

Product Model: 4114214470

输入电压：175~265Va.c.

Input current: 8A Max

频率:50Hz

输出电压：250~500VDC

输出电流：5.5A Max

Rated power: 2000W (input 250V~265V)

Degree of protection: IP66 (indoor or outdoor)

Manufacturer: Shenzhen Energy Efficiency Electric Technology Co., Ltd

The charging nozzle of the product conforms to the mainstream ergonomic design, with a better plugging and unplugging experience, and the end is also protected by a rubber cap.

There is a dense raised texture under the grip of the fuselage to enhance the grip of the car host.

The top is designed with an integrated lock plate.

Raised and snap-on designs at both ends for easy pressing.

There is also an orange latching button on the side.

In the latched state, the charging tip cannot be removed to avoid accidental unplugging of the tip.

Close-up of the end of the charging gun with a nine-hole tip.

A list of the scenes of holding the charging gun head of the product.

The measured length of the input power cord is about 291cm.

The length of the charger is about 25.3cm.

The body width is 115.12mm.

The thickness is 82.64mm.

The length of the output cable to the tip end is about 150.5cm. It can be seen that the overall length of Geely's 2kW portable DC charger is about 4.6 meters.

In addition, the weight of the product is measured to be about 4.8kg.

Geely 2kW portable DC charger dismantled

After reading the appearance display of Geely's portable DC charger, let's disassemble it and take a look at the internal materials and workmanship.

First, remove the non-slip pad on the bottom of the charger's body and hide the set screws inside.

Remove the back cover of the charger, make an aluminum alloy shell inside, and fill it with thermal conductive glue potting.

There is a connector inside the housing for connecting the button indicator board and the cooling fan.

Unscrew the set screws and remove the platen that holds the cooling fan and wires in place.

Remove the upper cover of the charger and create an aluminum alloy heat dissipation grille inside.

The indicator plate is connected to the aluminum housing by wires.

The wires are connected to the indicator board and two cooling fans are connected.

The housing is screwed to the inner aluminum alloy housing.

Unscrew the set screws to separate the housing from the aluminum housing.

The input wires are secured by a screw platen.

Clean off the encapsulant inside and proceed with disassembly.

The output conductors are also secured by means of a metal platen.

Unscrew the set screws, remove the pressure plate, and loosen the output cable.

The PCBA module is removed from the inside of the housing, and the inside is filled with thermally conductive adhesive.

The inside of the housing is filled with thermally conductive adhesive.

The heating element of the PCBA module is equipped with an aluminum heat sink and is insulated with high-temperature tape. Compatible inductor and capacitor components are also insulated with high-temperature tape.

The main control MCU is soldered on the back of the PCBA module, and the primary stage is distinguished by a dotted line, and the boundary is obvious.

The length of the PCBA module is about 198mm measured by vernier calipers.

The width of the PCBA module is about 94.9mm.

The thickness of the PCBA module is about 42.6mm.

The AC input wires are connected by wire welding.

The output wires are also connected by soldering.

The output wire is marked with a wire marker for marking the purpose of the wire.

The input is equipped with a fuse, varistor, blue Y capacitor, common mode inductor and PTC resistor, and two rectifier bridges on the left side and a heat sink.

Close-up of the fuse at the input end, and the lead and fuse body are coated with heat shrink tubing.

The varistor is from STE Matsuda Electronics, with a specification of 14D561K, and is used for surge overvoltage absorption.

The two safety X2 capacitors are from Yimanfeng and have a specification of 0.68μF.

The two common mode inductors are magnetically surrounded, insulated with bakelite boards, and insulated with tape.

The MZ21 PTC thermistor is used to suppress inrush currents at power-up.

Relays are used to short-circuit PTC thermistors to reduce losses. The relay is from Hongfa, model HF32FV-G, contact capacity 10A250VAC, coil voltage 12V.

There is a relay for output control on the left side, two inductors in the middle, a resonant capacitor at the bottom of the inductor, and a PFC boost inductor and a rectifier bridge on the left side.

The two rectifier bridges are from YJ Yangjie Technology, with a model of GBU3008, a specification of 30A 800V, and are connected in parallel.

The film capacitor specification is 1.5μF 450V and is used for rectifier filtering.

The STM32F334R8T6 MCU is a mixed-signal MCU with integrated DSP and FPU, a Cortex-M4 CPU clocked at 72MHz, 64KB Flash, and 12KB SRAM. It has an I2C interface, an SPI interface, three USART interfaces and a CAN bus interface.

Close-up of the crystal oscillator that provides the clock to the MCU.

Close-up of PCB-reserved MCU communication terminals.

The driver used to drive the PFC switch is from Jewalt, model JW9624, which is a dual-channel, high-speed, low-side gate driver that supports driving MOS transistors, GaN and IGBTs. The device contains two independent gate drive channels, supports 4.5A peak current, supports independent channel output control, is compatible with TTL and CMOS drive levels, and operates from 4.5-20V.

Jewalt JW9624 Profile Information.

The PFC switch is from Shangyangtong, model SRC60R078BSTG, NMOS, withstand voltage 600V, conduction resistance 70mΩ, TO-247 package.

The PFC boost inductor is magnetically surrounded, insulated with a bakelite board at the bottom, and insulated by wrapping tape.

The PFC rectifier tube is from Sanan Integration, model SDS065J010C2, silicon carbide diode, withstand voltage 650V, 135°C current is 13A, and it is in TO-220-2L package.

The two film capacitors are from Fengming and are specified at 0.1μF 630V.

The side of the PCBA module is welded with high-voltage filter capacitors and auxiliary power modules.

The high-voltage filter capacitor is from Fengbin and has a specification of 470μF 500V.

The half-bridge switch is from Dongwei Semiconductor, model OSG60R031HZF, withstand voltage 650V, conduction resistance 31mΩ, and TO247 package.

The resonant inductor is wound with a PQ32 magnetic core and wound with high-temperature tape.

The resonant capacitor specification is 0.056μF 1000V, and the two are connected in parallel.

The transformer is wound with PQ36 magnetic core and wound with high-temperature tape for insulation.

输出使用四颗三安集成SDS065J010C2碳化硅二极管组成整流桥。

The three output filter capacitors are from Fengbin, and the specification is 10μF 550V.

A film capacitor is filtered in parallel with an electrolytic capacitor.

There are also two rectifier bridges at the output end, from Yangjie Technology, model GBU3008, and both rectifier bridges are broken off a pin.

继电器来自友利通，型号UT30-12（L），触点容量30A，线圈电压12V。

The output is equipped with a relay, a filter capacitor, a filter inductor, and a blue Y capacitor.

Hongfa HF32FV-G relay is used for output control.

The output filter inductor is made of magnetic surrounding, and the bottom is insulated with bakelite board.

The output film filter capacitor specification is 0.1μF 630V.

The fuse is used for output overcurrent protection and is insulated with heat shrink tubing.

The auxiliary power supply board is insulated with high-temperature tape.

The back of the small plate is also wrapped with high-temperature tape.

The front of the small board is welded with filter capacitors, switch tubes, transformers, rectifier tubes and filter capacitors (which have been removed).

The back side is soldered with the main control chip and feedback optocoupler.

The primary main control chip is from Tongjia Technology, model LD7575, which is a current mode controller with built-in high-voltage start-up circuit.

初级开关管来自吉林华微，型号JCS10N80C，NMOS，耐压800V，导阻1Ω，采用TO220MF封装。

The transistor type TIP31C, NPN type triode, withstand voltage 100V, is used in TO220 package.

The transformer is wound with PQ26 magnetic core, and the core is wound with high-temperature tape insulation.

Two optocouplers are used for the output voltage feedback function.

The output rectifier tube is from Jilin Huawei, the model is HBR20150S, the specification is 150V20A, and the TO220 package is used.

The output filter capacitor is from Lelon.

The specification is 1800μF 16V.

The two filter capacitors are from Ruby and are specified at 16V330μF.

The output filter inductor is made of magnetic surrounding, and the bottom is insulated with bakelite board.

The auxiliary power supply board and high-voltage filter capacitor are removed, and the power supply control board is internal.

Solder and remove the power control board, solder two MCUs on one side of the board, and isolate the communication chip. The MCU on the left is used for charger communication control, and the MCU on the right is used for switching power supply control.

The back side is soldered to isolate the communication chip, op amp and memory.

MCU来自意法半导体，型号STM32F334R8T6，是一颗内置DSP和FPU的混合信号MCU，内置Cortex-M4 CPU，主频达72MHz，内置64KB Flash和12KB SRAM。 具备I2C接口，SPI接口，三个USART接口和一个CAN总线接口。

Close-up of the crystal oscillator that provides the clock to the MCU.

Close-up of PCB-reserved MCU communication terminals.

The 1117 regulator has an output voltage of 3.3V and is used to power the MCU.

Thermistors are used to detect internal temperature for overheating protection.

The two isolated drivers are from NOVOSENSE, model NSi6801BD, which is a single-channel optocoupler-compatible isolated gate driver with a peak source and sink current of 5A.

Three Everlight EL1019 optocouplers are used for isolated communication.

用于通信控制的MCU来自雅特力,型号AT32F415CBT7,内部集成Cortex-M4 CPU,具备DSP指令集,主频达150MHz。 芯片内部集成128KB FLASH和32K SRAM,具备I2C接口,USART接口,SPI接口,CAN接口以及SDIO。

NOVOSENSE NSi8221 bidirectional dual-channel digital isolator is used for communication between MCUs.

The isolated transceiver for the CAN bus is an isolated controller area network (CAN) transceiver from Chuantu Micro, model CA-IS3052, which meets the ISO11898-2 physical layer specification. The logic input and output buffers inside the device are isolated by a silicon dioxide (SiO2) insulated gate and are capable of withstanding isolation voltages up to 5000VRMS (60s) and typical CMTI ±150kV/μs.

川土微 CA-IS3052 资料信息。

Close-up of SRP LM2904A Universal Dual Op Amps.

Close-up of the connection wire used to connect to the indicator light and the cooling fan plate.

Close-up of the connector connected to the indicator light board.

Close-up of pads of a PCB-ready wireless communication module.

Close-up of two working indicators.

Three thermistors are soldered on the PCB board to detect the temperature rise inside the charger.

The 9 blue Y capacitors are all from STE Matsuda Electronics.

Close-up of the indicator light and the button board on the outside of the housing.

The connecting wires are connected to the PCB by soldering.

Close-up of SMD LED indicator.

Close-up of the micro-motion buttons.

The cooling fan is from Shenzhen Huaxia Hengtai Electronics, with a model of DA04020B12HH and a specification of 12V0.16A.

Next, disassemble the charging cable, first unscrew the fixing screws of the rear housing.

Remove the tail shell and remove the wire guard sleeve.

The wire jacket and the protective cover are connected by a wire rope.

Unscrew the set screws and remove the lock button to secure the pin.

Remove the keys and remove the latch.

Close-up of the return spring inside the lock.

It is equipped with a latch locking mechanism inside to prevent accidental loosening during charging.

Remove the latch housing and get a list of the external components of the latch.

It is equipped with a micro switch and a geared motor inside.

The geared motor drives the slider to realize the locking function.

Close-up of a micro switch used to detect if the latch is in place.

微动开关来自晋煜，壳体印有ZING EAR字样。

Another micro switch is used to detect the lock-up position.

When the latch is in place, the micro switch closes.

The micro switch is secured by pins and cut-outs.

The micro switch is from the southeast and is a WS3 series waterproof switch.

The motor output shaft is fixed with a snap deadbolt.

The connecting wires are designed with a waterproof seal.

There is an orange rubber seal between the charging gun head and the housing.

Close-up of the charging gun head shell and internal pins.

Close-up of two orange rubber seals.

Close-up of the internal connection wire of the charging cable.

There is a shielding net inside the wire.

The cable is secured by a cable tie clip.

Resistive jacket heat shrink tube insulation.

Cut open heat shrink tubing, close-up of internal resistance.

Close-up of the internal connector of the charging cable.

The internal pins of the charging cable are all provided with an orange sealing ring.

The orange seal is fixed to the pin.

A list of all dismantling and a family photo.

Summary of the dismantling of the charging head network

Finally, a list of core components of Geely Panda mini electric vehicle DC charger is attached for your convenience.

The Geely Panda mini electric vehicle DC charger is a portable design, similar in appearance to the on-board AC charging gun, with the charger body in the middle section and a charging circuit inside. The charger supports 175-265Vac input, the output voltage is 250-500VDC, the maximum output current is 5.5A, and the output power is 2kW. There is a cooling fan inside the charger to accelerate air circulation and dissipate heat.

Through the dismantling of the charging head network, it was learned that the Geely Panda mini electric vehicle DC charger is controlled by ST STMicroelectronics MCU, both MCUs are STM32F334R8T6, Shangyangtong and Dongwei semiconductor MOS transistors are used internally, and San'an integrated silicon carbide diodes are used for PFC rectification and output rectification.

The internal rectifier bridge of the charger comes from Yangjie Technology, and the high-voltage capacitor comes from Fengbin. The MCU that communicates with the vehicle is from Artery, and it is equipped with Chuantu Micro CA-IS3052 isolation transceiver. The PCBA module of the charger is potted and sealed as a whole, and the aluminum alloy shell is used inside the shell with a fan for air cooling and active heat dissipation to meet the needs of long-term charging.