Smart Low-Cost On-Board Charger for Electric Vehicles Using Arduino-Based Control

Jose Antonio Ramos-Hernanz, Daniel Teso-Fz-Betoño, Iñigo Aramendia, Markel Erauzquin, Erol Kurt and Jose Manuel Lopez-Guede ()
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Jose Antonio Ramos-Hernanz: Electrical Engineering Department, University of the Basque Country (UPV/EHU). Nieves Cano 12, 01006 Vitoria-Gasteiz, Spain
Daniel Teso-Fz-Betoño: Electrical Engineering Department, University of the Basque Country (UPV/EHU). Nieves Cano 12, 01006 Vitoria-Gasteiz, Spain
Iñigo Aramendia: Electrical Engineering Department, University of the Basque Country (UPV/EHU). Nieves Cano 12, 01006 Vitoria-Gasteiz, Spain
Markel Erauzquin: Electrical Engineering Department, University of the Basque Country (UPV/EHU). Nieves Cano 12, 01006 Vitoria-Gasteiz, Spain
Erol Kurt: Department of Electrical and Electronics Engineering, Technology Faculty, Gazi University, 06560 Ankara, Turkey
Jose Manuel Lopez-Guede: Automatic Control and System Engineering Department, University of the Basque Country (UPV/EHU), Nieves Cano 12, 01006 Vitoria-Gasteiz, Spain

Energies, 2025, vol. 18, issue 8, 1-18

Abstract: The increasing adoption of electric vehicles (EVs) needs efficient and cost-effective charging solutions. This study presents a smart on-board charging system using low-cost materials while ensuring safe and optimized battery management. The proposed system is controlled by an Arduino MEGA 2560 microcontroller, integrating Pulse-Width Modulation (PWM) for precise voltage regulation and real-time monitoring of charging parameters, including voltage, current, and state of charge (SoC). The charging process is structured into three states (connection, standby, and charging) and follows a multi-stage strategy to prevent overcharging and prolong battery lifespan. A relay system and safety mechanisms detect disconnections and voltage mismatches, automatically halting charging when unsafe conditions arise. Experimental validation with a 12 V lead-acid battery verifies that the system follows standard charging profiles, ensuring optimal energy management and charging efficiency. The proposed charger demonstrates significant cost savings (~94.82 €) compared to commercial alternatives (1200 €–2000 €), making it a viable low-power solution for EV charging research and a valuable learning tool in academic environments. Future improvements include a printed circuit board (PCB) redesign to enhance system reliability and expand compatibility with higher voltage batteries. This work proves that affordable smart charging solutions can be effectively implemented using embedded control and modulation techniques.

Keywords: electric vehicle; charging point; on-board charger; PWM; Arduino (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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