VEHICLE POWER CONVERTER
Project Details:
Our team designed and developed a compact automotive power converter system, delivering a complete solution that encompassed mechanical design, electronics development, assembly, testing, and product distribution. The project focused on creating a reliable and cost-effective device capable of converting 12V and 24V vehicle power systems into a stable 5V output for charging modern mobile devices.
The development process began with the design of the enclosure, where a key objective was to minimise manufacturing complexity and reduce production costs. Rather than creating multiple housing components, we engineered a single-part enclosure design that could interlock and attach to itself, forming a strong and durable protective housing around the internal electronics.
Alongside the mechanical development, we designed the electronic circuitry required for the power conversion system and integrated all electrical components within the enclosure. The device was engineered to connect directly to the fuse box of cars, trucks, and other vehicles, providing a convenient and reliable source of USB power.
A key feature of the product is its support for USB Power Delivery (USB-PD) and Programmable Power Supply (PPS) technology, enabling fast charging of compatible mobile phones, tablets, and other portable electronic devices. The electronics were carefully designed and tested to deliver efficient power conversion while supporting the charging requirements of modern consumer electronics.
The project also included the assembly of custom wiring harnesses and the integration of all electronic and mechanical components into the final product. Following assembly, comprehensive testing procedures were carried out to verify product performance, safety, and reliability prior to deployment.
The result is a robust and efficient automotive power converter that combines innovative enclosure design with reliable electronic performance. By reducing manufacturing complexity and optimising assembly processes, the final product delivers a cost-effective and scalable solution that enables fast charging of mobile devices directly from vehicle electrical systems.
The development process began with the design of the enclosure, where a key objective was to minimise manufacturing complexity and reduce production costs. Rather than creating multiple housing components, we engineered a single-part enclosure design that could interlock and attach to itself, forming a strong and durable protective housing around the internal electronics.
Alongside the mechanical development, we designed the electronic circuitry required for the power conversion system and integrated all electrical components within the enclosure. The device was engineered to connect directly to the fuse box of cars, trucks, and other vehicles, providing a convenient and reliable source of USB power.
A key feature of the product is its support for USB Power Delivery (USB-PD) and Programmable Power Supply (PPS) technology, enabling fast charging of compatible mobile phones, tablets, and other portable electronic devices. The electronics were carefully designed and tested to deliver efficient power conversion while supporting the charging requirements of modern consumer electronics.
The project also included the assembly of custom wiring harnesses and the integration of all electronic and mechanical components into the final product. Following assembly, comprehensive testing procedures were carried out to verify product performance, safety, and reliability prior to deployment.
The result is a robust and efficient automotive power converter that combines innovative enclosure design with reliable electronic performance. By reducing manufacturing complexity and optimising assembly processes, the final product delivers a cost-effective and scalable solution that enables fast charging of mobile devices directly from vehicle electrical systems.
