How does the main control board of Xin Orange Technology's 7KW new national standard charging pile achieve intelligent control?

The "Smart Control" of Xin Orange Technology's new national standard 7 kW charging pile main control board is not simply an MCU flashing program but integrates the four linkages of "sensing-decision-making-execution-communication" into a single 130×125mm industrial-grade PCB. Based on Xin Orange Technology's latest 7 kW charging pile main control board disassembly and mass production solutions for 2024-2025, it can be summarized into six core technical modules, all of which can be fully implemented with domestic chips.

1️⃣ Multi-Protocol Plug-and-Charge (Cloud-Vehicle-Board Instant Handshake)

• The main control board is equipped with a built-in Bluetooth/Wi-Fi/4G tri-mode communication module (e.g., Xingcheng XC-WF-207) + OCPP1.6J protocol stack

• Insert the gun → Mobile mini-program/vehicle-mounted NFC automatically pops up → Cloud authentication → Mainboard closes the relay in 0.8 seconds, no swiping required throughout the process

• BYD 7 kW Home Charging Station Test: Bluetooth BLE Broadcast to CP Duty Cycle Stabilized <1s, 4x Faster Than Traditional Card Swipe Process

2️⃣ AI Edge Power Scheduling (Peak Shaving + Off-Peak Automated Charging)

• Edge nodes run lightweight LSTM models (<2 MB), with inputs: historical load, real-time electricity prices, and remaining battery capacity

• The main control board automatically calculates the "optimal power curve" every 15 minutes, fine-tuning the PWM duty cycle in 1% steps, resulting in a 18-25% reduction in electricity costs for the user side

• Ankerui Park Case Study: With 100 7 kW piles online simultaneously, AI scheduling reduced the transformer peak load from 340 kW to 260 kW, achieving a peak shaving rate of 24%

3️⃣ Millisecond-level protection & self-recovery

• Domestic Dual MCU Architecture: Nuvoton N32G457 Main Controller + Lingdong Micro MM32F5270 Monitor

• – The main MCU runs the charging logic; the monitoring MCU independently samples current, temperature, and leakage current, capable of cutting off the relay within 200 µs to meet the hard requirement of the 2025 new national standard "30 ms power-off."

• Secondary self-recovery: Overcurrent/overtemperature first reduces power → recovers → retries 3 times before disconnection if still abnormal, reducing false trips by 60%

4️⃣ Full Lifecycle Remote Operations and Maintenance

• The main control board integrates a 4G CAT1 module with MQTT resume transmission capability; firmware differential OTA allows a 128 kB patch to be completed in 30 seconds with zero downtime

• The cloud-based digital twin provides real-time displays of relay activation counts, capacitor ESR, and fan speed. When the ESR exceeds the standard by 20%, it automatically generates a "Replace Main Control Board" work order, reducing maintenance costs by 55%

5️⃣ Smart Metering and Tariff Engine

• The metering front-end employs the JQ HT5015 SOC (6000:1 dynamic range, ±0.5% accuracy), featuring on-chip integration of an RTC and temperature sensor. It supports 4-tier time-of-use power measurement with direct pulse output, eliminating the need for an external energy meter

• The main control board stores a 12-month power consumption curve in flash memory, automatically matching peak/off-peak/flat electricity rates. The user app displays the "estimated electricity cost for this charge" in real time, delivering a Tesla home charger-like experience

6️⃣ Ultra compact and high-density integration

• Place within dimensions of 190×150 mm:

– Power devices: Silan Microelectronics 40A/650V IGBT+SiC hybrid package

– Drive power supply: Sunon 15W integrated transformer module

– Isolated Communication: Chuantuwei 5 kV Isolated 485+CAN

– Anti-interference: 4-layer board with buried blind holes + partitioned ground, passing ±8 kV contact discharge/±15 kV air discharge tests

→ Power density of 1.1 W/cm², a 40% improvement over the previous generation 7 kW board

Actual Test Results (Data as of December 2024)

• Plug-and-charge success rate: 99.3%

• AI-powered orderly charging reduces peak loads by 24%, cutting user-side electricity costs by 18%

• The fault self-recovery ratio is 58%, and the on-site attendance frequency has decreased from 0.8 times/year to 0.3 times/year

• OTA update with zero interruption, average download time of 28 seconds

Conclusion

Xin Orange Technology's new national standard 7 kW charging pile motherboard has upgraded the traditional "dumb pile" to a "real-time edge node" through a four layer intelligent closed loop of "communication authentication AI scheduling dual core protection cloud operation and maintenance"; Domestic chips have achieved complete coverage, with an overall BOM cost increase of only 7%, but they bring explicit value in peak shaving by 1/4, operation and maintenance by half, and comprehensive user experience benchmarking against major automobiles, becoming a standard solution for new residential areas and zero carbon parks by 2025. Welcome to inquire and purchase!