Plugzmart — a Chennai-based authentic tools producer (OEM) of EV chargers — obtained certification for its 60kW DC quick electrical car (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 autos and their parts.
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 parts 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.
Talking to The Higher India again in December 2022, co-founder Ragavendra Ravichandran mentioned, “A majority of EV chargers in India at this time 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 isn’t any help from Chinese language producers as soon as put in, which is a key situation.”
“We miss the technical stronghold of the imported merchandise and discover it troublesome to resolve points with out service help. As EV adoption will increase on the buyer 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 provide 75% cost in half-hour, is one other step in the direction of addressing this situation.
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 big 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 vitality area.”
“Our purpose is to supply end-to-end options that not solely handle the present wants of the electrical car sector but in addition pave the way in which for future improvements in sustainable vitality. By integrating sensible applied sciences, superior management programs, and IoT-enabled platforms, we purpose to create a seamless, environment friendly, and scalable vitality infrastructure that helps the worldwide transition to greener and extra sustainable transportation choices,” he provides.
Creating the quick charger
Talking to 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 deal with high-power charging options initiated about two years in the past. We went by 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, resembling voltage, present, and temperature to stop overheating and overcharging, making certain protected operation. The controller additionally allows clever load administration, balancing energy throughout a number of charging factors, enabling simultaneous charging of a number of EVs,” says Ragavendra.
“Attaining environment friendly warmth dissipation at such excessive energy ranges, minimising vitality losses, and stopping part injury have been vital challenges too. We additionally centered on making certain compatibility with a number of car fashions and integrating superior load administration options,” he provides. One of many key points with many frequent charging stations in India is their incapability to cater to totally different car 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 car’s onboard charger for faster vitality switch. The charger communicates with the car’s Battery Administration System (BMS) to find out the required cost degree and adjusts the ability 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 embody:
- 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 car.
- Energy Filters: Guarantee clear, secure energy output by lowering noise and harmonics, enhancing total charger efficiency.
The main supplies used within the manufacturing of this EV charger embody:
- Aluminium is used for warmth sinks and charger housing for its glorious warmth dissipation and light-weight properties.
- Copper wiring is employed for its excessive conductivity, making certain minimal energy losses.
So, how does this charger stand other than others within the business?
Ragavendra explains, “The charger encompasses a proprietary controller for clever load administration, permitting dynamic energy distribution and simultaneous car charging. It’s particularly designed for four-wheelers and dynamically adjusts energy output primarily based on the linked car’s battery capability and state of cost.”
However can we set up it at house?
The 60kW charger is designed for four-wheelers solely and might cost a car (with a bigger battery pack) from 0 to 80% in 60 to 90 minutes. For autos with smaller battery packs, it might probably 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 properties with adequate grid capability (340V+ AC provide). Nonetheless, most owners could go for smaller chargers (7-22 kW) attributable to house and electrical limitations. For individuals who can meet the necessities, establishing this quick charger requires a sturdy electrical infrastructure and house for cooling and air flow,” explains Ragavendra.
Creating parts in-house
The parts developed in-house embody the controller card, PLC module, and software program for load administration. What’s the PLC module? In accordance with Vivek, “The PLC (Energy Line Communication) module transmits information over the identical energy traces used for charging. This reduces set up complexity and permits real-time communication between the charger and the car’s onboard programs.”
“The PLC module allows the charger to barter with the car on how a lot energy it wants, making certain the car receives the optimum cost price. It ensures compatibility with varied car varieties and permits the charger to adjust to worldwide charging requirements, making it versatile for various environments,” it provides. In some programs, PLC modules are additionally concerned in enabling Automobile-to-Grid (V2G) communication the place the car 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 programs from trusted suppliers inside India and overseas, significantly from China and Taiwan, identified 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, “Now we have attracted curiosity from fleet operators, EV producers, and charging community operators.”
“A number of corporations, significantly in public transportation and fleet administration, have proven curiosity. Now we have obtained 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; Photographs courtesy Plugzmart)
