preface
Electric bicycles are a means of transportation for many people to go to work and pick up their children, and they are very used in daily life. EV chargers are products that are used every day, and many people consider the price first when buying to replace a damaged EV charger, and ignore the product quality. For electric vehicles, the quality of the charger is very important, which directly determines the safety of charging.
The charging head network has successively disassembled a batch of commercially available electric bicycle chargers, analyzed the internal power supply architecture and protection measures of the charger through dismantling, and analyzed the internal structure and design to understand the materials used in the brand charger. The following brings a summary of the disassembly of this batch of electric bicycle chargers, let's take a look at the similarities and differences inside.
AIMA
Emma 218W lithium battery charger
The output voltage of this special charger for lithium battery is 54.6V, and the output current is 4A, which is suitable for 48V 20-24Ah lithium battery. The charger comes with a 1-meter long power input cable and charging output cable, and the output cable is designed with anti-reverse connection to ensure the correct polarity. The charger has a built-in cooling fan to speed up the air flow and take away the heat generated by charging.
Through the dismantling of the charging head network, it was learned that the special charger for Emma lithium battery adopts the process of thermal conductive glue potting, and the primary switch tube and the secondary rectifier pipe use heat sink to dissipate heat with the fan, and the heat dissipation fan is connected through the connector. The charger is a flyback architecture inside, and the charging is controlled by a non-standard MCU, and feedback is carried out through the optocoupler to achieve constant voltage and constant current control.
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1. Dismantling report: Emma 218W lithium battery special charger
ALRIGHT
Aulet 109.2W electric bike charger
The Aolet electric bicycle charger is dedicated to 13 strings of lithium batteries, the output specification of the charger is 54.6V2A, and the output power is 109.2W. The charger is equipped with a figure-eight socket at the input end and is equipped with a 1.2-meter long output cable. The charger adopts a flyback structure, seals the shell, and is compact in size while removing the cooling fan, making the use experience better.
Through the dismantling of the charging head network, it was learned that the electric bicycle charger of Aolite adopts a flyback switching power supply architecture, uses the main control chip LD5763E Tongjia Technology with Longteng LSD65R180GT MOS tube, Haisimei MBR20200 Schottky diode rectification, and uses Jichuang IN1V002B1 op amp for output control, and the internal electrolytic capacitors are all from Fuzhiqing. The PCBA module inside the charger is glued and reinforced in a large area, and the internal materials and workmanship are very reliable.
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1. Dismantling report: Aaulet 109.2W electric bicycle charger
Aulet 168W Electric Bike Charger
This electric bicycle charger is dedicated to lithium batteries, supporting charging 10 strings of lithium batteries, with an output specification of 42V 4A and an output power of 168W. The charger uses a pinword socket and is equipped with a 1.2 meter long output cable. Compared with traditional electric vehicle chargers, the efficiency of the Aolet charger is greatly improved, not only the cooling fan is removed, but also the volume is greatly reduced, which further improves the user experience.
Through the dismantling of the charging head network, it was learned that the PCBA module inside the charger of Aulet is wrapped with an aluminum alloy heat sink to enhance the heat dissipation performance. The charger has a built-in NXP TEA2016AAT 2-in-1 controller, the PFC switch is from MPSEN, the LLC switch is from Anhai, and the synchronous rectifier is from Huarui Micro. The internal high-voltage filter capacitor is from Emerald, the output filter capacitor is from Fuzhiqing, and the input and output terminals are equipped with fuses for overcurrent protection, and the internal materials and workmanship of the charger are very reliable.
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1. Dismantling report: Aoleite 168W electric bicycle charger
Aulet 218.4W electric bike charger
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.
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1. Dismantling report: Aolet 218.4W electric bicycle charger
Aulet 273W Electric Bike Charger
The output power of this electric bicycle charger is 273W, which is dedicated to lithium batteries, supports charging 13 strings of batteries, and the charger adopts a Zizi power cord and is equipped with a 1.5-meter-long new national standard output cable. 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 PFC controller adopts onsemi NCP1654, the LLC controller adopts NCP1399, and the PFC switch and LLC switch are from Anhai. The PFC rectifier tube adopts Tyco Tianrun G3S06510A silicon carbide diode, and the synchronous rectifier chip adopts the MP6924A of Xinyuan Semiconductor.
The charger is equipped with an MCU board for output control, using a MS51FB9AE MCU from Nuvoton, and also using a MK9019 synchronous buck converter from Marex to power the MCU board and other chips. The internal high-voltage filter capacitor of the charger comes from Yide, the output filter capacitor comes from Wanyu, and the input terminal is equipped with a varistor for surge protection, and the internal materials are reliable.
FUYUANDIAN富源电
Fuyuan Electric 168W new national standard electric bicycle charger
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.
Jurry Juyuan
Juyuan 105W lead-acid battery charger
This EV charger supports 48V lead-acid battery charging with a maximum output current of 1.8A. The charger comes with a 1-meter power cord and a 1-meter output cable to meet the needs of daily charging and use. The charger has a built-in cooling fan, which can accelerate the airflow and take away the heat generated inside during charging, ensuring stable operation. The charger supports the use of 48V18-20Ah batteries, and adopts the new national standard terminal block.
Through dismantling, the charging head network learned that the electric vehicle charger of Juyuan adopts a partial potting process, and the PCBA module is fixed in a plastic shell, which is potted and sealed, which increases mechanical strength and improves reliability while preventing moisture. The internal switch tube is equipped with a heat sink to dissipate heat through the fan airflow.
The charger is a flyback architecture, using a primary main control chip RM6500S sub-Cheng micro, a Schottky diode for rectification, and an output using Huimang micro-MCU for charging control. The input and output of the charger are equipped with fuses for overcurrent protection, and the PCB is soldered with two NTCs for airflow temperature and PCB temperature detection, respectively, and the safety measures are in place.
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1. Dismantling report: jurry Juyuan 105W new national standard lead-acid battery charger
Juyuan 176.4W lead-acid battery charger
This EV charger supports 48V lead-acid battery charging with a maximum output current of 3A. The charger comes with a 1-meter power cord and a 1-meter output cable to meet the needs of daily charging and use. The charger has a built-in cooling fan, which can accelerate the airflow and take away the heat generated inside during charging, ensuring stable operation. The charger supports the use of 48V20Ah batteries and adopts the new national standard terminal block.
Through the dismantling of the charging head network, it was learned that the electric vehicle charger of Juyuan adopts a partial potting process, and the PCBA module is fixed in a plastic shell and potted and sealed, which increases the mechanical strength while preventing moisture. The charger is a flyback architecture, using the primary main control chip RM6500S Yacheng Micro, and the output is controlled by Huimang Micro MCU. The charger input and output are equipped with fuses for overcurrent protection, and safety measures are in place.
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1. Dismantling report: Juyuan 176.4W new national standard lead-acid battery charger
Sunra New Day
Xinri 109W smart lithium battery special charger
This lithium battery charger of Xinri has a maximum output voltage of 54.6V and supports charging 13 strings of lithium batteries. The length of the charger's input power cable and charging output cable is 1.1 meters, which can meet the daily charging needs of electric vehicle battery packs. The output current of the charger is 2A, the maximum output power is 109W, and the built-in fan is used for heat dissipation to reduce the temperature rise.
Through the dismantling of the charging head network, it was learned that the PCBA module of the Xinri lithium battery charger was clearly marked for the first time, the input and output wires were connected by soldering, and the cooling fan was connected through the connector. Inside, the Ombo OB3840 controller is used for flyback switching power supply control, Huimang Micro MCU is used for voltage feedback and constant current control, the built-in thermal diode is combined with the optocoupler for temperature detection and overheating protection function, and the output control is carried out by CR Micro MOS tube.
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1. Dismantling report: Xinri 109W smart lithium battery special charger
TAILG
Tailing 109W lithium battery charger
This lithium battery charger has a maximum output voltage of 54.6V and supports charging 13 strings of lithium batteries. The charger comes with a 1-meter power cord and a 1-meter output cable to meet the daily charging needs of the EV battery pack. The output current of the charger is 2A, the maximum output power is 110W, and the built-in fan is used for heat dissipation to reduce the temperature rise.
Through the dismantling of the charging head network, it is learned that the Tailing lithium battery charger fixes the PCBA module in the shell, the input and output wires are connected by soldering, and the cooling fan is connected through connectors. The internal control chip is used for voltage feedback and constant current control, the built-in thermal diode is used for temperature detection and overheating protection functions, and the lamp is controlled by optocoupler.
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1. Dismantling report: Tailing 109W lithium battery charger
Yadea Yadea
Yadea 144W lead-acid battery charger
Yadea EV charger supports charging 48V lead-acid batteries, and the charger comes with a 1.8m power cord and a 60CM output cable to meet the needs of daily charging. The charger has an output current of 3A, which can meet the charging of 10-22Ah batteries, and the versatility is also good. In addition, the charger also has a built-in cooling fan, which takes away the heat generated inside in time and makes it more stable to use.
Through the dismantling of the charging head network, it was learned that Yadea's electric vehicle charger adopts a potting process, and the heating element fixes the heat sink and dissipates heat through the fan. The charger is a flyback architecture, the primary uses a power chip with a silkscreen SPY180A5, the secondary uses a diode for rectification, and uses a silkscreen-printed SPW20F50-1 chip for charging management, and an LED indicator for charging status indication. The internal materials are solid, and the craftsmanship is quite good.
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1. Dismantling report: Yadea 144W lead-acid battery charger
Yadea 180W graphene lead-acid battery charger
Yadea's charger supports charging 60V lead-acid batteries, and the charger comes with a 1.8m power cord and a 60CM output cable to meet the needs of daily charging. The output current of the charger is 3A, which can meet the charging of 10-22Ah batteries, and the versatility is also good. In addition, the charger also has a built-in cooling fan to take away the heat generated inside, making it more stable and reliable.
Through dismantling, the charging head network learned that the Yadea lead-acid battery charger adopts a thermally conductive adhesive potting process, and the heating element is fixed in the aluminum heat sink, which is dissipated through the built-in fan. The charger is a flyback architecture, the primary uses a PI SC1060E power chip, the secondary uses a diode for rectification, and uses a silkscreen SPW20F50-1 chip for charge management, and an LED indicator for charging status indication. The internal materials are solid and the craftsmanship is good.
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1. Dismantling report: Yadea 180W graphene lead-acid battery charger
Yadea 480W graphene battery charger
Yadea's charger has an output voltage of 58.8V, an output current of 10A, and supports charging 14 strings of lithium batteries. The charger comes with a 1.5m input cable and a 60cm output cable to meet daily use. The charger has a built-in cooling fan, which can dissipate the heat generated during high-power fast charging in time and reduce the temperature rise. The output line of the charger adopts an anti-reverse connection design to ensure the correct polarity and safe use.
Through dismantling, the charging head network learned that the Yadea graphene battery charger adopts the LLC switching power supply design, the internal rectifier bridge, switch tube, and rectifier tube are all fixed on the heat sink, and the transformer and other components are fixed by glue. The charger uses NXP's TEA19161 primary controller, with a standard-free MCU for charging control, and controls the two-color LED indicator for charging status display, which is intuitive and easy to use.
Related Reading:
1. Dismantling report: yadea 480W graphene battery charger
Summary of the charging head network
The above is a summary of the dismantling of the electric bicycle charger by the charging head network, through the disassembly, it is understood that generally the smaller power electric vehicle chargers use the flyback architecture, and the Yadea 480W charger uses the LLC architecture to improve the conversion efficiency due to the large power. The charger is equipped with a cooling fan and a heat sink on the switch tube to improve the heat dissipation capacity.
There are several chargers, the PCBA module adopts partial potting, and the bottom of the component and the PCBA module are potted as a whole to improve heat dissipation performance and weather resistance. The rest adopts a conventional design, and the components are glued and reinforced to prevent loosening caused by vibration. The charger is equipped with MCU for charging control, and the PCBA module is equipped with a thermistor for overheating protection to ensure safe use.