Development of Battery Charging System for EV

Abstract

The rapid growth of Electric Vehicles (EVs) has created an increasing demand for efficient and reliable battery charging systems. The performance and lifespan of an EV battery are directly dependent on the quality of its charging system, making its development a critical engineering challenge. Many existing systems face issues related to voltage instability, thermal management, and energy inefficiency. In this paper, we present the development of a Battery Charging System for Electric Vehicles operating at 48 V and 10 A. The proposed system employs a Constant Current/Constant Voltage (CC/CV) charging methodology along with overvoltage and overcharge protection to ensure safe and efficient energy transfer. This paper makes a detailed analysis and comparative study of various charging topologies, discussing the merits and demerits of each method with respect to efficiency, cost, and complexity. The system is validated through simulation and hardware testing, demonstrating stable output performance under varying load conditions, making it suitable for light-duty EV applications.

Introduction

A Battery Charging System for Electric Vehicles (EVs) is designed to safely and efficiently transfer electrical energy from an external source to an EV’s lithium-ion battery using controlled charging methods. Due to rising environmental concerns and the shift away from fossil fuels, EV adoption is increasing, making reliable charging systems essential. The most commonly used technique is the Constant Current/Constant Voltage (CC/CV) method, and the proposed system operates at 48 V and 10 A for light EVs like scooters and e-rickshaws, using a DC-DC converter with safety protections to prevent issues such as overcharging and overheating.

The literature review highlights several related works. Research by Revanth B.C (2022) examines different EV charging levels and converter designs, emphasizing efficiency, safety, and grid integration but noting the need for precise sensors and higher system complexity. Samyak Negrale (2023) focuses on Battery Management Systems (BMS), covering SOC, SOH, thermal control, and protection mechanisms, highlighting improved battery performance but again pointing to cost and complexity challenges. Shahid Aziz Khan (2024) proposes a compact planar inductor-rectifier design for wireless EV charging with improved power density, though it introduces thermal management and manufacturing difficulties.

Conclusion

The development of an efficient battery charging system is essential for ensuring the safe and reliable operation of Electric Vehicles. A few years back, EV charging systems were bulky and inefficient, but with advancements in power electronics, more compact and efficient solutions are now achievable. The proposed 48V 10A Battery Charging System using the CC/CV charging method demonstrates stable and efficient energy transfer suitable for light-duty EV applications. With the growing global demand for Electric Vehicles, well-designed charging systems will continue to play a vital role in accelerating the adoption of sustainable transportation.

References

[1] Revath B C1, Tanmayee R2, Prashanth C Veeru3, Nuthan B S4, Vishwas K Singh5, Gowtham B6 A “Review on Electric Vehicle Charging Systems”.2022 [2] Samyak Nagrale1, Ankit Waghmare2, Tanmay Sahare3, Achal Nagwanshi4, Ishika Sakhale5, Dr. Jyoti Sathe “Literature Survey on EV battery management system”, 2023 [3] Shahid Aziz Khan 1, (Graduate Student Member, IEEE), Yanghe liu 2, (Member, IEEE),Mengqi Wang 1, (Senior Member, IEEE), Guanliang Liu1, (Student Member, IEEE), Jae Seung Lee2, Abhilash Kamineni3, (Member, IEEE), AND Shivam Chaturvedi” Integrated Super Planar Inductor-Rectifier Design for EV Drive”,2024

Copyright

Copyright © 2026 Shraddha S S, Sahana M Reddy, Sahana M S, Sandhya D P, Dr. Chandrashekar S M. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.