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

Author

Listed:
  • 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)

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.

Suggested Citation

  • Jose Antonio Ramos-Hernanz & Daniel Teso-Fz-Betoño & Iñigo Aramendia & Markel Erauzquin & Erol Kurt & Jose Manuel Lopez-Guede, 2025. "Smart Low-Cost On-Board Charger for Electric Vehicles Using Arduino-Based Control," Energies, MDPI, vol. 18(8), pages 1-18, April.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:8:p:1910-:d:1631127
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    References listed on IDEAS

    as
    1. Shyh-Chin Huang & Kuo-Hsin Tseng & Jin-Wei Liang & Chung-Liang Chang & Michael G. Pecht, 2017. "An Online SOC and SOH Estimation Model for Lithium-Ion Batteries," Energies, MDPI, vol. 10(4), pages 1-18, April.
    2. Matija Kovačić & Maja Mutavdžija & Krešimir Buntak, 2022. "New Paradigm of Sustainable Urban Mobility: Electric and Autonomous Vehicles—A Review and Bibliometric Analysis," Sustainability, MDPI, vol. 14(15), pages 1-23, August.
    3. Jenn, Alan & Springel, Katalin & Gopal, Anand R., 2018. "Effectiveness of electric vehicle incentives in the United States," Energy Policy, Elsevier, vol. 119(C), pages 349-356.
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