Future-proof charger design for electric two-wheelers and three-wheelers

As electric vehicles advance, battery-powered two- and three-wheelers are rapidly gaining popularity around the world. In India, electric autorickshaws will account for 60% of the three-wheeler market as of April 2025. This rapid adoption is driving demand for compact, efficient, and reliable charging solutions. Two newly released example designs from Power Integrations are ready-to-manufacture power supply designs suitable for small, sealed enclosures. Requiring no vents or fans for cooling, they offer improved reliability and resistance to dust and humidity.

■ PRDR-1063: 720W Charger for Electric Motorcycles
170VAC to 280VAC input supported with active PFC
Over 94% efficiency at 230VAC input
- Output voltage range of 26VDC to 60VDC
- Constant voltage regulation with better than ±1% accuracy
・Output battery current range of 0A to 24A
- ±5% higher precision constant current regulation

■ DER-996: 1650W Charger for Electric Tricycles
170VAC to 280VAC input supported with active PFC
Over 94% efficiency at 230VAC input
- Output voltage range of 26VDC to 60VDC
- Constant voltage regulation with better than ±1% accuracy
・Output battery current range of 0A to 24A
- ±5% higher precision constant current regulation

Both designs offer flexible constant-current/constant-voltage (CC/CV) control via a fixed on-board configuration or via a CAN interface directly connected to an external microcontroller and the vehicle's battery management system. Each vehicle receives a charge optimized for its specific battery chemistry, state-of-charge and thermal conditions, ensuring the charger design is future-proof. Featuring switching frequencies up to 360 kHz with a power factor of 0.99 or better, transformer size can be minimized, and these designs utilize four Power Integrations devices to achieve the highest level of integration.

Includes 600V half-bridge power devices and safety isolation devices. HiperLCS-2 Chipset
- Built-in ultra-low reverse recovery diode HiperPFS-3 Power Factor Correction IC
- 900V silicon switch and FluxLink feedback InnoSwitch3-EP Flyback switching power supply IC
・Zero power loss X capacitor automatic rapid discharge IC CAP Zero-3

Product documentation related

Product datasheets and reference designs can be downloaded immediately from the manufacturer's website below.

• RDR-1063: 720W Charger for Electric Motorcycles
• DER-996: 1650W Charger for Electric Tricycles
• HiperLCS-2 Product Page
• HiperPFS-3 Product Page
• InnoSwitch3-EP product page
• CAPZero-3 product page

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