On-Board Charger
On-Board Charger/ On-Board Range Extender
An on-board charger is an additional power source that is integrated into electric vehicles to support the main battery. It is used to extend the vehicle’s driving range beyond the limit that is set with the battery alone. Typically, onboard chargers can be internal combustion engines or fuel cells that generate electricity to charge the battery when needed. This system is best suited for longer journeys without the need for frequent recharging. They play a crucial role in bridging the gap between conventional vehicles and fully electric ones, making electric mobility more accessible and versatile.
Design of an On-Board Charger
The design of an onboard charger varies depending on the type of vehicle they are used in, but generally, it consists of the following components:
- Engine(Power source): The primary component of an onboard charger is the power source, which generates energy that is converted into electricity to charge the vehicle’s battery. This can be an internal combustion engine (ICE) running on gasoline or diesel, a fuel cell that generates electricity through a chemical reaction between hydrogen and oxygen, or in some cases, a small turbine engine.
- Permanent Magnet Generator or Alternator: In vehicles with an IC Engine, a Permanent magnet generator or alternator is used to convert the mechanical energy into electrical energy. This electrical energy is then used to charge the battery or directly power the electric motor that drives the vehicle.
- Control System: A control system is used to manage the electricity generated and coordinate its interaction with the vehicle’s battery and electric drivetrain. This system regulates the power output of the On-board charger based on factors such as battery state of charge, driving conditions, and power demand.
On-Board Charger Manufacturer: Innotec Power
Innotec Power is the manufacturer of On-Board Charger and Range Extenders for Global EV OEMs. Our range of open frame DC Gensets are designed to easily integrate and work as an auxiliary power source to charge the batteries on Electric and Hybrid Vehicles. We use the most trusted engines that are compatible with global emission norms. Our in-house manufactured Permanent Magnet Alternators/ Generators are highly efficient and lightweight making the whole system optimized.
Working with Innotec, gives OEMs the opportunity to customize the mechanical and electrical features of the charger according to their vehicles.
Get in touch with us to discuss more about custom DC On-board charger/ Range Extender.
What is the need for an On-Board Charger?
The need for an onboard charger arises from the limitations of current battery technology and the infrastructure for electric vehicles (EVs). Fully electric vehicles have their own great benefits, but they still face challenges related to range anxiety and long charging times. Here are some specific reasons why onboard range extenders are necessary:
- Addressing Range Anxiety: Range anxiety is one of the most common problems faced by longer distance running EVs. Many consumers fear running out of battery charge before reaching their destination or charging stations, making them hesitant to adapt to the EV revolution. Onboard chargers provide an additional source of power that can remove the range anxiety by extending the vehicle’s driving range beyond what is possible with the primary battery alone.
- Increasing Driving Range: The range of EVs are increasing with improvements in battery technology but it may still not be sufficient for some consumers. Those who frequently travel long distances or live in areas with limited charging infrastructure face this problem the most. Onboard chargers provide that extra range for them, allowing drivers to travel farther between charges.
- Overcoming Charging Infrastructure Limitations: In regions with limited or unreliable charging infrastructure, onboard chargers provide a practical solution for EV drivers. They reduce dependence on charging stations and offer a more reliable means of extending range when necessary, especially in remote or underserved areas.
- Transitioning to Electric Mobility: Onboard chargers can play a crucial role in helping the transition to electric mobility by offering a familiar driving experience with the added benefits of electric propulsion. They provide a bridge between conventional internal combustion engine vehicles and fully electric vehicles, allowing consumers to gradually adopt electric technology without compromising on range or convenience.
Diversity of On-board Chargers:
The operation of onboard chargers varies depending on the specific technology employed. In hybrid electric vehicles (HEVs) and plug-in hybrid electric vehicles (PHEVs), the internal combustion engine directly drives the wheels or acts as a generator to charge the battery when needed. In contrast, range-extended electric vehicles (REEVs) primarily rely on electric propulsion, with the onboard chargers serving solely as a generator to charge the battery.
