Mornsun Reliable Power Solution for Electric Two-wheeler, Help to Ensure the Quality and Reducing Time to Market
CONTENTS
The electric two-wheeler industry is fast growing
Transportation options for daily travel have become more convenient and diverse, and people often tend to choose a more lightweight vehicle - electric two-wheelers (also call EV two-wheelers, E-scooters) for short-distance travel. Compared with electric vehicles, electric two-wheelers have the advantages of high applicability, high maneuverability, easy maintenance and low price.
According to ResearchandMarkets, the global electric two-wheeler market was valued at $49.7 billion in 2022 and is expected to reach $80.6 billion by 2027. In particular, the electric two-wheeler market is growing at an impressive rate in China and India. With its large population, government incentives (NEMMP & FAME Ⅱ), rising oil prices and improved charging infrastructure, India has become the second-largest producer and manufacturer of two-wheelers in the world.
Key challenges for the electric two-wheeler industry
Global manufacturers have invested in launching their products first to capture a market that is growing rapidly. Though a wide range of products available from various manufacturers has given consumers more choices, it has also brought risks and challenges. Some experts are concerned that many manufacturers, in an attempt to ship products quickly and capture the market first, are not taking full account of the quality, safety and durability of their products and are launching products that have not been fully tested and inspected, leading to safety incidents. These risks have been confirmed by a number of fires involving electric two-wheelers in recent years, and these risks make people hesitant to buy electric two-wheelers.
Ensuring the quality and reliability of the products on the market is the main challenge facing the electric two-wheeler industry.
Mornsun Reliable Power Solution for Electric Two-wheeler
According to an expert team formed by the Indian government to analyze the causes of fires in electric two-wheelers, one of the main causes is the absence of a BMS or an inadequate and inappropriate BMS design for electric two-wheelers. A Battery Management System (BMS) is an electronic monitoring system that measures and monitors the operating status of the battery to prevent undesirable conditions such as discharging, overcharging, overheating and so on. If an electric two-wheeler is not equipped with a BMS, the user does not know the exact operating situation of the battery. Inadequately designed, inappropriately low-quality BMS can not manage the battery well and can not prevent serious heating of the battery pack caused by actions such as overcharging or discharging, which may lead to battery fire or explosion. The power supply is the core part of the BMS, and choosing a reliable, market-proven power supply should make it easier to meet the needs of manufacturers to get their products to market faster, while ensuring product quality and reliability.
With 25 years of experience in the power supply industry, Mornsun offers a wide range of power supplies, including ACDC converters, DCDC converters, IC and transformer components, most of which are marked with UL/CE/CAS/BIS and other safety standards and tested in the market, providing customers with one-stop reliable power supply solutions.
Taking the common 48V Li-ion battery BMS system of electric two-wheelers as an example, the main power supply takes power directly from the battery pack. Influenced by charging and discharging, the voltage fluctuation range at both ends of the battery pack is wide, usually from 36VDC to 56VDC, so the main power supply generally needs to meet a wider input voltage range. In addition, the main power supply power to the BMS control circuit unit, lighting unit, alarm system unit and other possible units, different units require different power.
Based on the above requirements, Mornsun recommends the non-isolated DC/DC converter K78UXX-1000R3 with an ultra-wide input range of up to 17-75VDC, with an output current of up to 1A, i.e. to cover the voltage fluctuation range from the battery, but also to meet the total power requirements for supplying multiple components.
As the control chip is sensitive to interference signals from the external environment, it is necessary to add an isolated DC/DC power supply to the transceiver. We recommend the fixed input DC/DC converters such as the B_XT-1WR3 series and B_S-1WR3, etc., which are UL/EN/BS EN/IEC 62368 compliant and feature compact size, excellent performance and low cost, with SIP and SMD package options to suit application requirements.
For the signal communication unit at the back end of the BMS, the current mainstream is a discrete solution: Digital isolators + Interface IC as the signal isolation communication part, and driver IC + Transformer to provide an isolated power supply for it. The disadvantage of a discrete solution is that circuit design is complicated, PCB layout area is large, and maintenance is difficult. Mornsun recommends an integrated solution: an isolated CAN transceiver TD541SCANH to replace discrete solutions. The TD541SCANH integrates power, isolation and communication in an ultra-small and ultra-slim DFN package. It offers a baud rate of up to 1Mbps and is AEC-Q100 compliant, helping to simplify system design, reduce system size and time-to-market, and ease maintenance.
Although the discrete solution is difficult to design, it has the advantage of low cost, so for some economical electric two-wheelers, Mornsun can also provide a reliable discrete solution: Dual-channel digital isolators SCM3725ASA + High-speed CAN transceiver SCM3425ASA as the signal isolation communication part， and Transformer driver IC SCM1212B + Transformer CTTF0505 provide isolated power for the communication part. All these components meet the AEC-Q100/200 automotive standard with high reliability.
Summary
Various favorable factors have pushed various electric two-wheeler manufacturers to continue their innovation and technology to provide the market with various types of specifications for electric two-wheelers. Mornsun offers reliable and proven power solutions for all major systems of electric two-wheelers (Lithium Battery BMS, Control System, DC Converter System, Alarm System, Electrical Control System and Instrumentation System), reducing customers' design and verification time and helping customers to bring reliable, safe and durable products to market faster.
