Plugzmart — a Chennai-based unique gear producer (OEM) of EV chargers — obtained certification for its 60kW DC quick electrical automobile (EV) charger from the Automotive Analysis Affiliation of India (ARAI) late final month. ARAI is a analysis institute with the Union Ministry of Heavy Industries, which develops requirements for automobiles and their elements.
This is a vital growth in advancing an indigenous EV infrastructure in India given the way it has been unable to maintain up with the rising fleet of home EVs. What’s extra, the indigenous manufacturing of its (charging infrastructure) key elements is at a nascent stage.
However what does the ARAI certification imply for Plugzmart’s 60kW DC quick charger? This certification for the Chennai-based startup’s quick charger and proprietary controller card signifies their compliance with stringent operational security requirements and effectivity norms in India.
Chatting with The Higher India again in December 2022, co-founder Ragavendra Ravichandran stated, “A majority of EV chargers in India in the present day are being imported and are of low high quality. They’re largely imported from China. [This is because] Chinese language chargers are priced low, however there is no such thing as a help from Chinese language producers as soon as put in, which is a key subject.”
“We miss the technical stronghold of the imported merchandise and discover it tough to resolve points with out service help. As EV adoption will increase on the patron and business sides, the requirement for chargers from producers of two, 3, and 4-wheelers and cost level operators goes to scale quickly,” he added. The ARAI certification for his or her quick DC charger, which may supply 75% cost in half-hour, is one other step in the direction of addressing this subject.
In the meantime, talking on the milestone of attaining this certification for his or her DC quick charger, Vivek Samynathan, founder and CEO of Plugzmart, says, “Securing the ARAI certification for our 60kW DC quick charger, particularly with our controller card, is a major achievement for us. As a part of our broader imaginative and prescient, we’re devoted to constructing a complete ecosystem of {hardware} and software program options within the power area.”
“Our objective is to supply end-to-end options that not solely handle the present wants of the electrical automobile sector but additionally pave the way in which for future improvements in sustainable power. By integrating sensible applied sciences, superior management techniques, and IoT-enabled platforms, we goal to create a seamless, environment friendly, and scalable power infrastructure that helps the worldwide transition to greener and extra sustainable transportation choices,” he provides.
Growing the quick charger
Chatting with The Higher India, Vivek says, “The event of Plugzmart’s 60kW DC Quick Charger started across the similar time as different DC charger tasks with a devoted give attention to high-power charging options initiated about two years in the past. We went by means of roughly three prototypes earlier than arriving on the present mannequin. Every prototype underwent rigorous testing to refine effectivity, energy administration, and security requirements.”
Over these two years, there have been a number of challenges they needed to overcome within the growth course of. “The first problem was designing a proprietary controller card that might seamlessly deal with high-speed charging whereas sustaining a compact measurement,” he provides.
What does a controller card do? “The controller card manages energy distribution, communication, and security protocols throughout charging. It displays vital parameters, comparable to voltage, present, and temperature to stop overheating and overcharging, guaranteeing protected operation. The controller additionally permits clever load administration, balancing energy throughout a number of charging factors, enabling simultaneous charging of a number of EVs,” says Ragavendra.
“Reaching environment friendly warmth dissipation at such excessive energy ranges, minimising power losses, and stopping part harm have been vital challenges too. We additionally centered on guaranteeing compatibility with a number of automobile fashions and integrating superior load administration options,” he provides. One of many key points with many widespread charging stations in India is their incapacity to cater to totally different automobile fashions and their battery specs.
How does the charger work?
As Vivek explains, “The 60kW DC Quick Charger converts AC energy from the grid into DC energy utilizing an inner rectifier (AC/DC converter). It delivers high-power DC output on to the battery, bypassing the automobile’s onboard charger for faster power switch. The charger communicates with the automobile’s Battery Administration System (BMS) to find out the required cost degree and adjusts the facility output dynamically.”
Going additional, Vivek additionally explains a few of its key specs:
- Energy Output: 60kW
- Enter Voltage: 340-480V AC
- Output Voltage Vary: 100V – 1000V DC
- Effectivity: 95%+
- Working Temperature: -20°C to +50°C
Elements and standing aside
Main Elements of the DC Quick Charger embrace:
- Rectifier (AC/DC Converter): Converts incoming AC energy to DC energy for sooner battery charging.
- Cooling System: A sophisticated air or liquid cooling system ensures the charger operates at protected temperatures throughout high-power operation.
- Proprietary Controller Card: Manages real-time operations, security protocols, and communication with the automobile.
- Energy Filters: Guarantee clear, secure energy output by lowering noise and harmonics, enhancing general charger efficiency.
The foremost supplies used within the manufacturing of this EV charger embrace:
- Aluminium is used for warmth sinks and charger housing for its wonderful warmth dissipation and light-weight properties.
- Copper wiring is employed for its excessive conductivity, guaranteeing minimal energy losses.
So, how does this charger stand other than others within the business?
Ragavendra explains, “The charger contains a proprietary controller for clever load administration, permitting dynamic energy distribution and simultaneous automobile charging. It’s particularly designed for four-wheelers and dynamically adjusts energy output based mostly on the related automobile’s battery capability and state of cost.”
However can we set up it at dwelling?
The 60kW charger is designed for four-wheelers solely and might cost a automobile (with a bigger battery pack) from 0 to 80% in 60 to 90 minutes. For automobiles with smaller battery packs, it could possibly go from 0 to 75% cost in half-hour.
“Whereas this charger is primarily designed for public or business use, it may be put in in residential houses with adequate grid capability (340V+ AC provide). Nonetheless, most householders might go for smaller chargers (7-22 kW) as a consequence of house and electrical limitations. For individuals who can meet the necessities, establishing this quick charger requires a strong electrical infrastructure and house for cooling and air flow,” explains Ragavendra.
Growing elements in-house
The elements developed in-house embrace the controller card, PLC module, and software program for load administration. What’s the PLC module? In keeping with Vivek, “The PLC (Energy Line Communication) module transmits information over the identical energy strains used for charging. This reduces set up complexity and permits real-time communication between the charger and the automobile’s onboard techniques.”
“The PLC module permits the charger to barter with the automobile on how a lot energy it wants, guaranteeing the automobile receives the optimum cost charge. It ensures compatibility with varied automobile varieties and permits the charger to adjust to worldwide charging requirements, making it versatile for various environments,” it provides. In some techniques, PLC modules are additionally concerned in enabling Automobile-to-Grid (V2G) communication the place the automobile can return energy to the grid, thus serving to with grid stabilization.
Nonetheless, not each part is developed in-house. Some are nonetheless imported. Vivek explains, “We supply semiconductors, rectifiers, and cooling techniques from trusted suppliers inside India and overseas, notably from China and Taiwan, recognized for his or her experience in high-power electronics.”
Price and buyer base
A single unit of the 60kW DC Quick Charger with its proprietary controller card and PLC module prices round Rs 8 to Rs 9 lakh relying on customisation and amount.
In the meantime, talking on the client base for his or her quick charger, Vivek says, “We now have attracted curiosity from fleet operators, EV producers, and charging community operators.”
“A number of corporations, notably in public transportation and fleet administration, have proven curiosity. We now have acquired preliminary commitments and buy orders from fleet operators and EV charging infrastructure builders, together with native authorities initiatives for public charging,” he provides.
(Edited by Pranita Bhat; Pictures courtesy Plugzmart)
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