Diseño personalizado de PCB para cargadores de vehículos eléctricos: Integración de V2H y energía solar

An off-the-shelf custom ev charger pcb design is often the single point of failure that halts a product launch, leading to expensive certification delays and lost market share. Many hardware teams attempt to integrate advanced features like Vehicle-to-Home (V2H) and solar charging onto generic boards, only to face insurmountable issues with thermal management, component communication, and regulatory compliance. This ad-hoc approach creates a product that is unreliable in the field and uncertifiable for the market.

This technical brief bypasses surface-level discussions and focuses on the critical R&D decisions required for a successful build. We will analyze the specific engineering challenges, from integrating bi-directional V2H chips onto the mainboard to the practicalities of using wireless CT clamps for dynamic load balancing. We’ll also cover component-level choices, like specifying Tier 1 automotive-grade relays, and outline a rapid prototyping workflow to get a functional sample manufactured in days, not months.

Bi-Directional Ready: Can We Add V2H Chips to the Mainboard?

Vehicle-to-Home (V2H) functionality is currently achieved through a modular architecture of separate components, not a single integrated chip on the charger’s mainboard.

Current Hardware and Protocol Standards

Current V2H systems rely on a distributed hardware architecture to manage bidirectional power flow. Implementations use dedicated, separate inverters and converters to handle the demanding task of converting DC power from the vehicle’s battery into grid-synchronized AC power for a home. This power management is coordinated through established communication protocols like CHAdeMO and SunSpec, which ensure safe and reliable energy transfer. This modular approach is the prevailing commercial standard because it effectively isolates the high-power conversion process from the main control logic, ensuring system stability and safety.

Technical Challenges for Direct Integration

Integrating full V2H functionality onto a single mainboard chip introduces significant technical barriers. A single chip would have to manage both high-power conversion and complex control logic for grid synchronization, tasks that generate substantial heat. Effective thermal management becomes a primary engineering problem; dissipating the heat from a compact, integrated chip without compromising performance or lifespan is extremely difficult. These combined challenges of power, control, and heat are why the industry continues to rely on separate, specialized components to ensure operational reliability and safety.

Future Focus on Miniaturization

As bidirectional charging becomes more common, the industry’s long-term strategic goal is miniaturization. The focus of R&D is to reduce the physical size and overall system cost of V2H technology. This progress depends heavily on advancements in semiconductor design, which could eventually lead to more integrated and compact solutions. Such innovation is essential for making bidirectional chargers more affordable, accessible, and easier for electricians to install in residential and commercial settings.

Dynamic Load Balancing (DLB): Is Wireless CT Clamp Integration Possible?

By 2026, wireless CT clamp integration for Dynamic Load Balancing is a mature, standard-issue solution, driven by its massive advantages in installation cost and scalability over traditional hardwired systems.

Wireless Integration is Standard Practice by 2026

Yes, integrating wireless CT clamps for Dynamic Load Balancing (DLB) is not just possible—it’s now a mature and widely adopted technology. At KelyLands, we confirm this approach is standard for both new and retrofit installations. It completely eliminates the need for complex and costly hardwiring runs from the charger back to the main electrical panel. The market has decisively shifted to wireless to support rapid infrastructure deployment.

• The market has shifted decisively toward wireless solutions to support rapid infrastructure scaling.
• Our EV chargers are designed to be compatible with leading wireless energy monitoring systems.

Installation and Scalability Advantages

The primary benefit of a wireless DLB system is the significant reduction in installation complexity and cost. It bypasses the need for expensive electrical work like running new conduit or cable trenching. This makes deployments faster and far more scalable, especially in large commercial properties, apartment complexes, or existing buildings where disruptive work is not feasible.

• Wireless CT clamps enable retrofit-friendly installations without major electrical upgrades.
• Clients can deploy and expand their charging networks more efficiently due to lower upfront labor and material costs.

Key Communication Protocols: LoRa, WiFi, and RF

Our engineering team integrates various wireless communication protocols to meet different site requirements. LoRa is excellent for long-distance coverage in large parking areas, while WiFi and RF are reliable and cost-effective for typical residential and commercial setups. Choosing the right protocol depends entirely on the installation environment and performance needs.

Performance: Wired vs. Wireless Solutions

While wireless is the dominant choice for flexibility, KelyLands also supports hardwired CT clamps for specific use cases. A wired connection offers absolute zero-latency reliability and is immune to network interference. This makes it the preferred option for mission-critical industrial applications or sites with extreme RF interference where guaranteed performance outweighs installation convenience.

• Wireless solutions are ideal for most commercial and residential uses where flexibility is key.
• Wired connections provide maximum offline resilience for sites requiring guaranteed, instantaneous load adjustments.

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Using automotive-grade relays is a non-negotiable for manufacturing durable EV chargers, as they are engineered for high-current loads and extreme environmental conditions that standard commercial components cannot reliably handle.

The decision to use Tier 1 automotive-grade relays directly impacts the long-term safety, reliability, and market viability of an EV charger. While commercial-grade components may lower initial production costs, they introduce significant failure risks when subjected to the sustained high currents and harsh operating environments common to charging infrastructure. Automotive relays are specifically designed to mitigate these risks, making them the correct engineering choice for building a robust product.

Performance and Reliability in Wide Temperatures

Automotive-grade relays are built to perform reliably across a wide temperature range, typically from -40°C to +125°C. This operational stability is critical for EV chargers that must function in diverse global climates without performance degradation. Whether installed in a frozen Scandinavian garage or a sun-baked parking lot in the Middle East, the component’s core switching function remains consistent. This is paired with high mechanical longevity, with ratings often exceeding one million cycles, which drastically reduces the risk of component failure over the charger’s lifespan.

High-Current Switching Capability

These relays are engineered to manage the significant electrical loads of EV charging. Models capable of switching up to 130A are available, safely handling the amperage required for rapid charging sessions in 7kW, 11kW, and 22kW units. This capability is essential for safe and efficient power delivery. They also feature enhanced thermal management to prevent overheating during sustained, multi-hour use, a common scenario that can cause lesser components to fail.

Environmental Sealing and Durability

A fully sealed design protects the relay’s internal mechanisms from dust, moisture, and other environmental contaminants. This is not a luxury but a requirement for equipment that will be installed outdoors and exposed to the elements. This robust construction ensures long-term durability, protecting against ingress and withstanding the physical shock and vibration that may occur during shipping, installation, and daily use. Sourcing relays that meet stringent compliance standards for demanding environments is a core part of our design philosophy.

Rapid Prototyping: Can We 3D Print a Working Sample in 7 Days?

A functional, 3D-printed EV charger prototype in seven days is not just possible—it’s a standard part of our OEM development process, enabled by modern digital fabrication.

From Weeks to Days: Current Prototyping Speeds

The industry standard for rapid prototyping has fundamentally changed. Manufacturing cycles that once took weeks now compress to just 24 to 72 hours for many components. KelyLands uses these advancements to make a 7-day turnaround for a functional sample a practical target for most OEM projects.

• Advanced additive manufacturing compresses traditional PCB and housing production timelines.
• For specific designs, we can fabricate functional prototypes in a matter of hours, allowing for immediate design validation.
• This speed reduces development costs and accelerates the entire product-to-market cycle.

Core Technologies for Fast Turnaround

Our prototyping process uses key digital fabrication technologies that bypass the need for traditional tooling in the early stages. This allows for the direct and immediate creation of complex parts from digital designs.

• Precision 3D printing creates multi-layer and complex physical enclosures directly from CAD files.
• Direct imaging systems and laser processing enable the quick production of functionally complex PCBs.
• These tools provide the flexibility needed for customized board geometries and rapid iterative design changes.

KelyLands’ 7-Day Feasibility and Process

A 7-day prototype is feasible and aligns with our standard sample lead time of 7 to 15 days. The process starts with a design review to confirm that component complexity and material needs fit within the rapid production timeline.

• The 7-day goal typically covers an initial functional sample using 3D-printed parts and a verified PCB.
• The final timeline depends on project complexity, material availability, and the extent of functional testing required.
• This rapid prototyping stage is a standard part of our OEM/ODM service before committing to mass production tooling.

Conclusión

Building a market-ready EV charger starts at the mainboard level. Integrating features like V2H readiness and wireless dynamic load balancing directly onto the PCB creates a powerful, efficient product. Selecting automotive-grade components for the design ensures long-term reliability and safety for the end-user.

If you are developing a custom EV charger, our engineering team can help validate your hardware requirements. Contact us to discuss your project specifications and explore our OEM solutions.

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