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EV CHARGER DESIGN

EV Charger
Design

AC-DC and DC-DC stages. Compact, efficient, production-ready
charging solutions with EMI compliance and BMS integration.

AC-DC & DC-DC
Power Stages
CC-CV-CP
Charge Profiles
Multi-Stage
Compact Design
EMI
Compliant
EXPERTISE

Complete Charger Engineering

We design EV chargers that balance efficiency, size, and cost. Our charger designs incorporate PFC front-ends, isolated DC-DC stages, and intelligent charge algorithms — from portable chargers to DC fast charging modules, with full EMI compliance and BMS integration.

PFC Front-End

Active Power Factor Correction for high efficiency and low harmonic distortion. Bridgeless totem-pole and interleaved topologies.

Isolated DC-DC

LLC resonant, phase-shifted full bridge, and flyback topologies. Soft-switching for high efficiency and low EMI.

Charge Algorithms

CC-CV-CP charge profiles with temperature compensation. Adaptive algorithms for battery health optimization.

BMS Integration

Seamless communication with BMS over CAN and Modbus. Coordinated charge control, fault handling, and thermal management.

OUR WORK

Products We've Built

Production-ready charger designs for EV and energy storage applications.

Portable EV Charger — Compact Design
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Portable EV Charger — Compact Design

Compact portable charger with PFC front-end and LLC DC-DC stage. Designed for size and weight optimization without sacrificing efficiency.

PFC LLC Portable
DC Fast Charger Module
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DC Fast Charger Module

High-power DC fast charger module with modular architecture. Supports parallel operation for scalable charging stations.

DC Fast Modular CAN
On-Board Charger (OBC)
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On-Board Charger (OBC)

Integrated on-board charger for electric two-wheelers. Bi-directional capability with V2L (Vehicle-to-Load) support.

OBC Bi-directional V2L
SPECIFICATIONS

Technical Capabilities

Deep expertise across charger design engineering.

Topologies

  • LLC Resonant Converter
  • Phase-Shifted Full Bridge (PSFB)
  • Active Clamp Flyback
  • Totem-Pole Bridgeless PFC
  • Interleaved Boost PFC

Power Range

  • Portable: 500W – 3.3kW
  • On-Board (OBC): 1kW – 22kW
  • DC Fast: 15kW – 60kW modules
  • Efficiency: 93–97% peak
  • Power density optimization

Communication

  • CAN 2.0B / CAN FD (BMS link)
  • Modbus RTU / TCP
  • OCPP 1.6 / 2.0 (station mgmt)
  • ISO 15118 (Plug & Charge)
  • UART / RS-485 (diagnostics)

Standards & Compliance

  • IEC 61851 (EV charging)
  • IEC 61000-4-x (EMC immunity)
  • CISPR 32 (EMI emissions)
  • IS 17017 (India EV charger)
  • UL 2202 (EV charging equipment)
OUR PROCESS

From Concept to Production

A structured approach to charger development.

01
System Architecture
Power level, topology selection, thermal budget
We define the charger architecture based on input voltage range, output requirements, efficiency targets, and form factor constraints. This includes PFC topology selection, DC-DC stage design, and thermal management strategy.
02
Power & Control Design
Magnetics, loop compensation, charge algorithms
Detailed power stage design including transformer/inductor design, MOSFET selection, snubber circuits, and control loop compensation. Firmware development covers charge algorithms (CC-CV-CP), BMS communication, and fault management.
03
PCB & EMI Testing
Layout, thermal design, pre-compliance EMI
PCB layout optimized for EMI performance, thermal management, and safety creepage/clearance. Pre-compliance EMI testing identifies issues early. Thermal validation ensures reliable operation across the full load and temperature range.
04
Certification & Production
Compliance testing, safety certification, manufacturing
Support for IEC 61851, EMC, and safety certification testing. Production handoff includes complete design package, manufacturing test procedures, calibration routines, and end-of-line test specifications for reliable mass production.

Need a charger designed?

Let's discuss your charging requirements.

Get in Touch
mohit@maqlabs.com
+91 8600175076