Charge Profile & Control
CC/CV, multi-stage, float, and custom charge profiles with precise current and voltage regulation matched to your battery chemistry.
Consultancy · Battery Charger Design
Battery chargers that are fast, safe & efficient
We design chargers and adaptors from 12 W to 2 kW for Li-ion, LiFePO4, and lead-acid — CC/CV and custom charge control, power stage and magnetics, protection, and BMS integration — validated in simulation and proven on the bench. The same power-electronics engineering we teach and ship every day.
Charge CurrentBattery Voltage
Every charger is proven in simulation — CC/CV control, protection, and thermals — then verified on the bench for safety and efficiency.
12W–2kWCharger power range
CC/CV+ custom profiles
Li·LiFePO4·PbBattery chemistries
Sim→BenchValidated & safe
What We Deliver
Complete charger engineering — accurate, protected, and efficient
Charge control, power stage, protection, and thermals are engineered together — because a charger has to be safe and reliable every single cycle, not just on the bench once.
Power Stage & Magnetics
Charger topology (flyback, LLC, buck/boost), magnetics, switch and rectifier selection — tuned for efficiency, size, and cost.
Protection & Safety
Over-voltage, over-current, over-temperature, reverse-polarity, and short-circuit protection designed in from the very start.
BMS Integration
Charger-to-BMS interfacing — charge enable, current and voltage limits, and communication — for reliable, safe pack charging.
Thermal & Reliability
Loss budgeting, thermal design, and derating so the charger runs cool, keeps efficiency high, and lasts across many cycles.
Efficiency & Testing
Measured charge curves, efficiency, standby power, and protection/safety behaviour against targets — with iteration until it holds.
Our Process
A clear, six-step path from battery spec to a tested charger
Predictable stages, checkpoints you can review, and a safe, measured charger at the end.
Step 01 · Requirements
Requirements & Battery Profile
Battery chemistry, pack voltage and capacity, target charge current and profile, input source, and constraints are captured into a clear, testable specification.
- Chemistry, pack voltage & capacity
- Charge current & profile (CC/CV)
- Input source & safety constraints
Step 02 · Topology
Charger Topology & Architecture
The right charger topology and control architecture are chosen through a trade-off study and feasibility check against your targets.
- Flyback / LLC / buck evaluated
- Isolation, efficiency & cost trade-offs
- Topology & control approach confirmed
Step 03 · Simulation
Simulation & Charge Control
Power stage, magnetics, and CC/CV charge control are designed and validated in simulation — charge curves, stability, and protection — before hardware.
- CC/CV control & loop design
- Charge-curve & stability simulation
- Protection behaviour verified early
Step 04 · Prototype
Prototype & Power Stage
PCB layout, magnetics build, protection and sensing, component sourcing, assembly, and the first supervised charge of a real prototype.
- PCB & magnetics build
- Protection & current/voltage sensing
- First supervised charge test
Step 05 · Validation
Test, Safety & Efficiency
Bench testing of the full CC/CV cycle, efficiency, standby power, thermals, and every protection path — iterating until the charger is safe and on-spec.
- CC/CV & taper behaviour verified
- Efficiency, standby & thermal checks
- Protection & safety validation
Step 06 · Delivery
Delivery & Documentation
Schematics, magnetics details, BOM, PCB files, and measured charge/efficiency/safety data are handed over with a walkthrough so you can move forward with confidence.
- Schematics, magnetics & BOM
- Measured charge, efficiency & safety data
- Walkthrough & complete handover
What You Receive
A charger you can measure, trust, and build
Every engagement ends with a tangible package — the design intelligence, the hardware, and the measured evidence that it charges safely and efficiently, ready for your next step toward a product.
- Charge-profile & control design
- Schematics and calculations
- Magnetics design (core, turns, gap)
- PCB layout and manufacturing files
- Bill of materials (BOM)
- Working charger prototype
- Measured charge / efficiency / safety data
- Documentation & handover
Built safe and efficient
- Protection designed in from day one
- Thermal and derating for a long service life
- High efficiency and low standby power
- Clean, reviewable design and documentation
- A clear path from prototype toward production
Inside The Work
From battery spec to a bench-measured charger
A look at how chargers actually take shape — profile, simulation, prototyping, and safety testing.
Where It's Used
Chargers for products, mobility, and energy systems
Consumer & product chargersCompact, efficient adaptors and chargers for devices and appliances.
E-bike, e-scooter & light EVSafe, efficient charging for light-mobility battery packs.
Power tools & appliancesFast, protected chargers for tool and appliance battery packs.
Solar & off-grid chargingSolar and off-grid charge controllers and battery chargers.
Industrial & lab chargersRobust chargers for industrial equipment and lab battery systems.
Custom multi-cell packsChargers matched to bespoke Li-ion, LiFePO4, or lead-acid packs.
Why Power4All
A team that simulates, builds, and teaches charging every day
Power4All is a power-electronics education and engineering platform — so your charger is guided by people who understand the chemistry, the power stage, and the safety.
Simulation-first proof
We build our own converter and charger simulators, so charge curves and control are validated and visualized before hardware — cutting cost and risk.
Real charger depth
Chargers and adaptors from 12W to 2kW across Li-ion, LiFePO4, and lead-acid — practical charging experience, not just slides.
Safety & protection focus
Protection and safe charging are designed in from the start, not bolted on — because a charger sits unattended with energy stored behind it.
Chemistry-aware design
Charge profiles and limits tuned to your exact chemistry — Li-ion, LiFePO4, or lead-acid — for battery health and cycle life.
Education-grade documentation
Because we teach, we explain. You get clear reports and documentation your team or examiner can actually follow.
Built to iterate
Chargers rarely hit every target on the first build. We plan for measurement, refinement, and a second pass so the result truly meets spec.
FAQ
Battery charger design — common questions
Chargers and adaptors from 12W to 2000W for Li-ion / Li-Po, LiFePO4, lead-acid, and NiMH — single-cell to multi-cell packs — with CC/CV, multi-stage, or fully custom charge profiles, including EV and light-mobility chargers.
Yes. We design the CC/CV (and taper, float, or multi-stage) charge control together with protection — over-voltage, over-current, over-temperature, reverse-polarity, and short-circuit — so charging is both accurate and safe.
Yes. We design the charger to work with your battery management system — charge enable, current and voltage limits, and communication — or advise on selecting a suitable BMS for your pack.
Absolutely. We analyse and simulate your current design, then re-engineer the power stage, magnetics, layout, control, and protection to improve efficiency, standby power, thermals, and safety margins.
Schematics and calculations, magnetics design, PCB layout and BOM, a working charger prototype, measured charge curves, efficiency, thermal and protection/safety data against targets, and complete documentation for handover.
Share your battery chemistry, pack voltage and capacity, target charge current and profile, input source, constraints, and timeline through the consultancy request form. We review it and send back a clear scope.
Start Your Charger
Need a battery charger designed or improved?
Tell us your battery chemistry, pack voltage and capacity, charge current, input source, and timeline. We'll propose the right topology and a clear path for simulation, prototyping, testing, and delivery.