Electric Vehicle Charger Structure

The structure of an electric vehicle charger mainly consists of a casing, circuit board (PCBA), power devices, a heat dissipation system, and protection components. Its design balances electrical safety, heat dissipation efficiency, and environmental adaptability.

1. Input and Output Interfaces

AC Input: Typically uses a two-prong or triangular socket, supporting a wide voltage input of AC 100-240V. Some models are certified by CCC, UL, etc.

DC Output: Equipped with a new national standard plug (such as T-type or X-type), featuring physical reverse connection protection and integrated communication wires for protocol handshaking between the charger and the battery pack, ensuring compatibility before charging begins.

2. Main Control Circuit and Power Supply Architecture The charger internally employs switching power supply technology. Common architectures include flyback and LLC resonant half-bridge:

Flyback Architecture: Primarily used in low-to-medium power chargers (e.g., 48V/2A). It features a simple structure and low cost. Common main control chips include Tongjia Technology LD5763E and Yijing Microelectronics EG1253.

PFC+LLC+SR Architecture: Applied to high-power models (e.g., 200W and above). It boasts high efficiency (up to 90%) and low heat generation. The main control often uses NXP TEA2016AAT two-in-one controller.

Isolation Design: Primary and secondary circuits are isolated using a high-frequency transformer to ensure user electrical safety.

3.Heat dissipation methods: Low-power models rely on natural heat dissipation from the metal casing or heat conduction through potting compound; High-power models have built-in cooling fans (such as the 6020 size) and aluminum heat sinks for active cooling.