Bengaluru, India

Electric Vehicle charger


Electric vehicles are becoming increasingly popular all over the world. EVs attract buyers with benefits including energy efficiency and environmental friendliness. Increasing EV use is one way to increase alternative domestic fuel use, which may contribute to more reliable energy supply, stable prices, and reduced greenhouse gas emissions. As EV usage grows, electric vehicle charging stations are the newest and most visible green building amenity, capable of continuously enhancing the property and communicating participation in a global building movement.

Product Features

Interactive LED lights are given for quick identification of the station status. Backlit LCD screens are made for easy reading of costs and station status. Smart Card enabled for authentication easy access for EV drivers. Credit card enabled to make the payment more easy. Convenient Access Panel made for easy installation and connectivity. The charger is protected by NEMA 3R make the charger suitable for outdoor use. The 4S charger is Suitable for charging all-electric or plug-in hybrid electric vehicles.

Project Scope

We designed and developed the product for client including Detailed engineering, Development of Prototypes, Design Validation, Manufacturing Drawings, and Development of Parts. Industrial design was not in iSol’s scope.


As per the clients Industrial design, no screw should be visible from the outside. Since all the parts are made in such a way they snap together, that leads to the complex design of the parts. Same time we managed to design the product easy for manufacturing, assembly, and service The EV charger connectors are heavy, the cables are stiff and almost all parts are made of plastic and they are assembled together by snaps. To take the whole weight of the product, 2 metal parts are added to the assembly, which directly transfers the load to the wall. iSol carried out Finite Element simulation/ Analysis for this and ensured that the design was safe.

Analysis for Electric Vehicle charger

For this FE Analysis Of EV Charging Station, we have considered to perform geometry clean up and meshing for the EV Charging Station and We carried out Static Analysis for the various loading conditions to determine the Stresses and Factor of Safety. In this analysis, the whole body of the connector (gun) is considered as a rigid body and 80 KG of hanging load is applied on it. Here different load conditions are analyzed as shown in the figure.

The number of nodes is 146392 and the number of elements is 402829 in the Finite Element Model with an Average Mesh Size of 3mm.

The material used in this EV charger are ADC 12 with Youngs Modulus of 71000MPa and Density of 2.74g/cm³, Nylon 66 with Youngs Modulus of 10000 MPa and Density of 1.36g/cm³, PC Macrolon with Youngs Modulus of 21400 MPa and Density of 1.28g/cm³ and FR4(PCB) with Youngs Modulus of 24000 MPa and Density of 1.85g/cm³.

EV charger is attached to the fixed wall and 80 kg load is applied on the connector (gun). Due to this load, the maximum displacement obtained is 4.52mm.

Overall Maximum Stress

The Overall Maximum yield Stress observed is 123.2 MPa.

By these analysis we observed that 80 KG of hanging load for all material which is mentioned below will undergo 4.52mm displacement. For Rear Enclosure Casting component of ADC 12 material undergo Von Mises stress of 123.22 MPa and it is less than the Yield Strength of 281 MPa so the minimum FOS observed is 2.28. For Holster component of PC Macrolon material undergo Von Mises stress of 33.45MPa and it is less than the Yield Strength of 89.6MPa so the minimum FOS observed is 2.68. For Lock Nut component of Nylon 66 material undergo Von Mises stress of 9.66MPa and it is less than the Yield Strength of 80 MPa so the minimum FOS observed is 8.28. For all the Components the Stress observed is within the yield Strength so it means Design is safe.

Packing Design of Electric Vehicle Charger

The S400 E V Charger packing box will occupy the product along with cables & accessories. The accessories include a Home charger with plug and cable, Wall-mount bracket, Wall mount template with sticky tapes, SC-branded hardwire box, Wall-mount screws. iSol has designed packing for the client electric vehicle charger. The project included conceptualization of packing, detailed engineering, prototype development, design validation, testing, and safety validation.

Input Given for packing design

3D models & Physical samples of the product, cables & accessories that all go inside the box, The cable will be assembled to the charger before packing in the consumer packing, Printed installation manual (per regulatory requirements), User manual, Amperage labels for breaker and charger


  • Geometry/pattern cutting is ensure for smooth opening of the box and contents.
  • Charger made visible first when the box is opened to gain a beautiful user experience.
  • Pull-out design could include both charger, plug, and cable together, and due to cable weight it may fall-outs but it is taken care in design.
  • Side boxes is containing all Tools, Papers, and WM brackets in compartmentalized sections.
  • Packaging materials are eco-friendly and the use of plastics is limited to protecting glossy surfaces on the charger and external sealing of the box from water ingress.
  • Paper pouches/boxes are used for tools and accessories.
  • Inks used for graphics are eco-friendly.