THE CHALLENGE
Design a complete lab-grade AC EV charger kit for hands-on hardware training. Full documentation package for assembly, testing, and OCPP commissioning.
THE SOLUTION
Architecture design, component selection and BOM, wire harness specification, assembly documentation, and OCPP commissioning guide. Independent consulting engagement.
RESULTS & OUTCOMES
Complete architecture documented
BOM with alternate sourcing
Wire harness specification
OCPP 1.6 commissioning guide
Training content integrated
This consulting engagement produced a complete lab-grade AC EV charger kit for use in hands-on hardware training programmes. The deliverable was a documentation package — not production hardware — enabling training organisations to source, assemble, and commission a working EVSE from scratch.
Scope of Work
The engagement covered architecture design (IEC 61851-1 compliant EVSE circuit), component selection with a fully sourced BOM including alternate parts from multiple distributors, wire harness specification with connector pinouts and crimping instructions, assembly documentation with step-by-step photographs, and an OCPP 1.6 commissioning guide for connecting to a backend system.
Control Pilot Circuit
The Control Pilot (CP) signal implementation follows IEC 61851-1 state machine exactly, enabling trainees to measure and understand each charging state transition (A through F) using standard lab equipment. The CP circuit is implemented discretely rather than with a dedicated IC, making the signal path fully transparent for educational purposes.
OCPP Integration
The commissioning guide walks through connecting the charger's embedded controller to an open-source OCPP 1.6 backend (OCPP.js server on a Raspberry Pi), demonstrating Authorize, StartTransaction, MeterValues, and StopTransaction message flows in a self-contained lab environment.
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Let's Scope Your Project
Eight years of production-proven hardware expertise — from first topology decision to regulatory sign-off.