All You Should Know About Electric Car Chargers - EVB

There are several types of Electric Vehicle (EV) charger connectors used worldwide. These connectors vary depending on the region and the type of charging station. The chart below lists some of the common EV charger connectors used in North America, European Union, China, and Japan.

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The North American Charging Standard (NACS) is an electric vehicle charging standard developed by Tesla. It is used on all North American market Tesla vehicles since 2012, and was opened for use to other manufacturers in 2022. In May of 2023, Ford announced that it will integrate NACS into its future electric vehicles

Demand for electric vehicle (EV) chargers has increased in recent years as more and more people choose to purchase electric vehicles. Therefore, the production of EV chargers has become an important area of development.Are you looking for charging pile PCB solutions?

EASHUB’s EV Charger PCB Solution

A charging pile refers to a charging device that provides energy supplement for electric vehicles, its function is similar to the gasoline dispenser inside a gas station, it can be fixed on the ground or wall, installed in public buildings (public buildings, shopping malls, public parking lots, etc.) and residential district parking lots or charging stations, and it can be used for charging various types of electric vehicles according to different voltage levels.

Functional requirements:

• Charging pile (peg) can realize timing
• Electricity counting,
• amount-counting charging.
• It can be used as a terminal for the public to purchase electricity.
• Meanwhile, in order to improve the efficiency and practicability of the public charging pile (peg), the functions of multi-charging of one pile (peg) and charging for electric bicycles will be added in the future.

Charger Types

According to the installation method:

• Floor-mounted charging pile,
• Wall-mounted charging pile.
• Floor-mounted charging piles are suitable for installation in parking spaces that are not close to the wall.
• Wall-mounted charging post is suitable for installation in parking spaces close to the wall.

According to the installation location.

• Public charging pile and special charging pile.
•  Public charging pile is built in the public parking lot (library) combined with parking berths, for social vehicles to provide public charging services charging pile. 
• Dedicated charging pile is the construction unit (enterprise) own parking lot (library), for the unit (enterprise) internal personnel use the charging pile. 
• Self-use charging pile is constructed in the individual’s own parking space (library), for private users to provide charging charging pile. Charging piles are generally built in combination with parking spaces in parking lots (depots). The protection level of charging piles installed outdoors should not be lower than IP54, and the protection level of charging piles installed indoors should not be lower than IP32.

According to the number of charging ports:

• One pile one charging
• One pile multi-charging.

According to the charging method:

• DC charging pile (bolt)
• AC charging pile (bolt)
• AC/DC integrated charging pile (bolt)

Technical requirements

• Working environment temperature: -20℃～+50℃;
•  Relative humidity: 5% ~ 95%;
• Altitude: ≤1000m;
• Installation location: outdoor;
• Seismic capacity: horizontal ground acceleration 0.3g; vertical ground acceleration 0.15g; the equipment should be able to withstand the simultaneous action of three continuous sine waves, and the safety factor should be greater than 1.67

Power requirements

• Input voltage: single-phase 220V;
•  Output power: single-phase 220V/5KW;
•  Frequency: 50Hz±2Hz;
• Allowable voltage fluctuation range: single-phase 220V±15%;

IP protection grade

AC charging pile (bolts) should comply with IP54 (in outdoor), and configure the necessary rain and sun protection devices;

Circuit board three-proof (moisture-proof, mold-proof, salt spray-proof) protection

Printed circuit boards, connectors and other circuits in the charger should be protected against humidity, mildew and salt spray, of which the anti-salt spray corrosion ability meets the requirements of Table 9 in GB/T 4797.6-1995 “Natural Environmental Conditions of Electrical and Electronic Products Dust, Sand and Salt Spray” so that the charger can operate normally in the outdoor humid and salt-spray-containing environments.

FeatureSpecificationQuality StandardIPC-A-600HStructural TechnologyHard board, soft board, soft and hard combined boardNumber of Layers1-32 layersSheet TypeCEM3, FR-4, Rogers, Teflon, High TgMaximum Size850mm x 560mmBoard Thickness Range0.2mm – 8mmCopper Thickness Range1/3oz – 15ozMinimum Hole Diameter0.15mmMinimum Line Width and Spacing0.05/0.05mmImpedance Control Accuracy±5%Surface Treatment ProcessLead-free HASL, OSP, ENIG, gold plating/electrical gold, immersion tin, immersion silverBoard Warpage Rate0.5%Vacuum Reflow Soldering Void Rate0.5%-2%

EASHUB has been focusing on providing highly reliable electronic assembly manufacturing services for 15 years, mainly focusing on medical, new energy, automotive electronics, security, communication, AI artificial intelligence and other fields. The core technical team members have more than 20 years of experience in electronic product design, development and manufacturing industry, and so far have provided highly reliable electronic assembly services for more than 300 customers in different industries in more than 40 countries and regions around the world.

EV charger PCB Guide

In this post, we will discuss its importance in the production of EV charger PCB assembly and explore the key considerations and steps involved in EV charger PCB assembly.

Designing the EV Charger PCB

PCB is one of the key components of electric vehicle chargers, and its good design plays a vital role in the performance and safety of the charger. Here are some key considerations to keep in mind when designing for an EV charger PCB:

Circuit Complexity: EV chargers are complex systems, and the PCB must be able to handle a large number of components, as well as high power and voltage levels.

Safety features: EV chargers must meet stringent safety standards, and EV charger PCB designs should include features such as fuses, surge protectors, and ground-fault protection to ensure user safety.

Heat dissipation: High power generates a lot of heat, and thermal management should be considered when designing the PCB to prevent overheating.

Signal Integrity: High-speed data transmission is critical for EV charger-to-vehicle communication, and the PCB must be designed to ensure signal integrity and minimize noise.

Manufacturability: An EV PCB design should be easy to manufacture and assemble, with clear instructions and a well-organized layout.

When the EV charger PCB design is complete, it is important to produce and test the PCB to ensure its functionality and safety.

EV Charger PCB Manufacturing and Assembly

An important part of EV charger PCB production is fabrication and assembly. The process involves multiple steps including PCB layout, fabrication and assembly.

PCB Layout

EV charger PCB layout involves designing the physical layout of the PCB, which includes placement of components, routing of traces, and adding any necessary markings or labels to make EV charger PCB manufacturing and assembly more convenient and usable.

Printed Circuit Board Manufacturing

After the EV charger PCB design layout is completed, the next step is PCB fabrication. The manufacture of EV charger should be completed by a professional power supply PCB manufacturing factory, such as EASHUB. This process is usually done by etching a pattern onto a copper-clad substrate in different layers depending on the purpose, which is then drilled and plated to create the desired circuit.

PCB Assembly

For more information, please visit Customized Ev Charging Pile.

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EV charger PCB assembly, including attaching electronic components to the PCB. There are two main techniques for PCB assembly:

Through Hole Technology (THT): In THT, components are inserted into drilled holes on the PCB and soldered to the other side of the board. This technique is typically used for large components or where components require additional mechanical support.

Surface Mount Technology (SMT): In SMT, components are mounted directly to the surface of the PCB, which reduces the size of the PCB and speeds up assembly.

During assembly, it is important to ensure that the EV charger PCB is properly aligned and that the components are properly soldered. During the EV charger PCB assembly process, quality control is crucial to ensure that the final product is safe and functional.

Testing the EV Charger PCB

Once the PCB is assembled, the final step is to test that it is safe and viable. Testing is critical to ensure the correct and safe operation of EV charger PCBs. Here are some types of tests that should be performed:

Electrical Testing: Electrical testing checks the continuity of the circuit and ensures that power flows correctly throughout the PCB.

Functional Test: The functional test checks that the EV charger is functioning properly and meeting its performance requirements.

Security and Compliance Testing:Safety and compliance testing is critical for EV charger PCBs. These tests ensure that PCBs meet safety standards and comply with regulatory requirements. Security and compliance testing may include:

Hipot (Hipot) Test: Hipot testing checks that a PCB can withstand high voltage levels without arcing or failing.

Environmental Testing: Environmental testing checks the performance of PCBs under different environmental conditions, such as high humidity, extreme temperatures, and vibration.

EMC Testing: Electromagnetic Compatibility (EMC) testing checks that PCBs do not emit excessive electromagnetic interference (EMI) and are not affected by other electronic equipment.

Security and compliance testing is often performed by third-party testing laboratories to ensure unbiased and accurate results. Passing safety and compliance testing is critical for bringing EV chargers to market.

FAQs:

Q1: Can PCB assembly for EV chargers be customized for different power levels?

A1: Yes, PCB assembly can be customized to support different power levels in EV chargers. The power capacity and associated components, such as power transistors, diodes, and capacitors, can be tailored to meet the specific power requirements of the charger.

Q2: What is the importance of PCB assembly in EV chargers?

A2: PCB assembly plays a crucial role in EV chargers as it enables the integration of various electronic components necessary for charging functionality, such as power management, communication modules, safety features, and user interfaces.

Q3: What are the key considerations for PCB assembly in EV chargers?

A3: Some important considerations include selecting suitable components, designing for thermal management, ensuring safety and compliance with industry standards, optimizing the layout for signal integrity, and addressing high power requirements.

Q4: What types of components are typically used in PCB assembly for EV chargers?

A4: EV charger PCBs may include components like power transistors, diodes, capacitors, resistors, voltage regulators, microcontrollers, communication ICs, relays, connectors, and various sensors.

Q5: Are there any specific certifications or standards that PCB assembly for EV chargers must comply with?

A5: Yes, EV chargers must comply with relevant safety and performance standards, such as IEC 61851 for charging infrastructure, ISO 15118 for communication protocols, and various regional standards like SAE J1772 in North America or IEC 62196 in Europe.

Q6: How do thermal considerations come into play during PCB assembly for EV chargers?

A6: Thermal management is critical to prevent overheating in EV chargers. Designers need to consider the dissipation of heat generated by power electronics components, such as the charging circuitry and power conversion elements, to ensure optimal performance and reliability.

Q7: Are there any specific challenges in PCB assembly for high-power EV chargers?

A7: High-power EV chargers pose challenges related to managing high currents, maintaining low resistance connections, minimizing voltage drop, and ensuring effective heat dissipation. Special attention is given to trace thickness, current-carrying capacity, and thermal vias.

Q8: Is it possible to outsource PCB assembly for EV chargers?

A8: Yes, many companies offer PCB assembly services for EV chargers. Outsourcing the assembly process can save time, ensure quality, and provide access to specialized expertise and equipment.

Q9: What testing procedures are typically conducted during PCB assembly for EV chargers?

A9: Common testing procedures include functional testing, electrical testing, inspection for soldering quality, and adherence to design specifications. Additional tests may be performed to ensure safety, such as insulation resistance tests and high-voltage testing.

Q10: How can I ensure the reliability and quality of PCB assembly for EV chargers?

A10: To ensure reliability and quality, it is important to work with experienced PCB assembly providers, adhere to industry standards, perform rigorous testing, select high-quality components, and follow proper manufacturing and assembly processes.

Conclusion

EV charger PCB fabrication and assembly is a critical part of production. A well-designed PCB that is properly manufactured and assembled is critical to the correct and safe operation of an EV charger. Careful consideration of circuit complexity, safety features, thermal dissipation, signal integrity, and manufacturability during EV charger PCB design is critical. Additionally, comprehensive  EV charger PCB testing including electrical testing, functional testing, safety and compliance testing is essential to ensure that PCBs meet their performance requirements and safety standards.

Ultimately, the quality of the EV charger PCB assembly determines the performance and safety of the EV charger. Therefore, it is very important to work with a reliable and experienced PCB assembly partner, like EASHUB, we can provide high-quality PCBs that meet the required standards and specifications, please contact us if you have this need.

Contact us to discuss your requirements of 7kw Ev Charger. Our experienced sales team can help you identify the options that best suit your needs.