DESIGN OF MOBILE CHARGING DEVICES FOR ELECTRIC VEHICLES BASED ON INTERNAL COMBUSTION ENGINE VEHICLES

Аннотация

The growing adoption of electric vehicles (EVs) requires the parallel development of flexible and accessible charging infrastructure. In remote or underdeveloped areas, access to grid-powered charging stations may be limited. This paper proposes the design of a mobile EV charging unit based on the platform of an internal combustion engine (ICE) vehicle. The mobile unit includes a compact onboard generator, power management system, and multi-standard charging outputs. Through simulation and prototype analysis, this paper evaluates energy conversion efficiency, charging capacity, and operational feasibility. The study demonstrates that ICE-based mobile chargers offer a viable transitional solution for EV infrastructure expansion in regions with limited electrification. Moreover, the paper discusses system cost-effectiveness, scalability, and environmental impact, providing a foundation for future optimization and integration intonational mobilitypolicies. Keywords: Mobile charging station, electric vehicle, ICE platform, charging infrastructure, energy conversion, rural mobility, off-grid solution,fuel-to-electricity efficiency 1.Introduction. Electric vehicles (EVs) are reshaping the landscape of modern transportation by offering an environmentally friendly alternative to internal combustion engine (ICE) vehicles. However, one of the major challenges facing EV adoption is the lack of sufficient and accessible charging infrastructure. While urban areas may see a growing number of stationary EV charging stations, rural and remote regions still suffer from grid limitations. In these regions, mobile charging solutionsoffer apromising alternative. In Uzbekistan, many national and regional roads pass through territories where neither high- voltage electricity networks nor stationary charging stations are available. These infrastructure gaps present risks to EV drivers, limit the range of operation, and delay mass transition from ICE to EV technology. Hence, developing self-contained mobile charging systems based on currently available vehicleplatforms is apractical step. This research explores thedevelopment of amobileEV charging system that uses anICE vehicle as its base. The goal is to create a self-contained charging unit capable of traveling to remote locations and providing emergency or planned charging services. The study focuses on technical design, energy efficiency, economic feasibility, and deployment strategy. 2.Methods 2.1.Conceptual FrameworkTheproposed system integrates the following key components: ICE vehicleplatform (such as a diesel-powered minivanor pickup) Onboard power generator (diesel or gasolineengine-driven alternator) Inverter and charge controller Battery storage (optional) CCS/CHAdeMO/Type2charging connectors Powermonitoringand safety systems The modular design enables flexibility in system configuration based on power needs, vehicle type, and geographic constraints. Additionally, a load management algorithm is proposed to https://ijmri.de/index.php/jmsi volume 4,issue7,2025 126 balance charging outputacross multiplevehicles. 2.2. Power System DesignA 20 kW diesel generator is selected based on a balance of portability and power output. The generator output is converted from AC to DC using a rectifier and controlled via an intelligent charge controller. The system supports fast charging at 10–15 kW andslowcharging at 3–7kW. Table1–System ComponentSpecifications Component Specification Base Vehicle 1.5-ton Diesel Truck GeneratorPower 20kW,220VAC Inverter 20kW,PureSineWave ChargeController MPPT,60–100A Charging Interface CCS2,CHAdeMO, Type 2 Fuel Tank Capacity 60liters AverageFuel Consumption 2.5L/hour (under full load) 2.3. Simulation and Testing ToolsSimulations were conducted using MATLAB Simulink and HOMER Pro to model energy flow, fuel consumption, and system response under varying loads. Field trials were simulated with synthetic EV fleet usage data including vehicle arrival rates, battery SoCranges, and charging preferences. 2.4.Environmental Assumptionsand MetricsPerformance metrics were evaluated under different ambient temperatures (−10°C to +40°C), altitudes (sea level to 1500 m), and fuel qualities. Indicators included: Energy conversion efficiency (%) Charging time(minutes) EmissionsperkWhdelivered (g CO₂/kWh) Equivalent EVrange added per literoffuel consumed (km/L-equivalent) Costper delivered kWh(UZS) 3.Results 3.1. Charging Time and CapacityA standard EV with a 40 kWh battery charged from 20% to 80% in approximately 70 minutes using the fast-charge mode (15 kW). In slow mode, the same rangewas achieved in 190minutes. Table2–EV Charging Resultsunder Various Modes Mode Power Charge Time (20%– Fuel Used Energy Delivered (kW) 80%) (L) (kWh) Fast Charge 15 70minutes 2.9 24 Slow 6.6 190minutes 3.5 24 Charge 3.2. Energy Efficiency and Conversion LossesThe system showed maximum conversion efficiency of 88% at 100% load. Below 50% load, efficiency dropped to 75%, and further down t