Project Report for Onboard Charger Manufacturing
Every electric vehicle has one: the onboard charger, which converts AC from the grid to DC for the battery pack. India’s EV production is fast expanding thanks to the PLI scheme, and every vehicle produced requires an onboard charger. Sharda Associates creates CA-certified OBC manufacturing project reports and has delivered over 45,500 of them. Starting at ₹2,999.
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What Is an Onboard Charger (OBC)?
An onboard charger (OBC) is an AC-to-DC power converter that is permanently installed within an electric vehicle. It transforms AC mains electricity (from a home wall socket or a public AC charging point) into the DC voltage needed to charge the car’s traction battery. Unlike an off-board fast charger, which converts AC to DC externally, the OBC is built inside the car and is a key EV component rather than an accessory.
OBCs are rated based on their power (kW) and output voltage. A basic EV two-wheeler battery may be charged in 4-6 hours using a 3.3 kW OBC and a 15A outlet. A 7.4 kW OBC can recharge a passenger EV in 6-8 hours. Premium EVs employ high-power 11-22 kW on-board chargers for faster AC home charging. Each EV produced in India requires one.
Market Demand — EV Production Scale
India’s EV two-wheeler production will reach 1 crore cumulative units by 2024, with annual production increasing by 40-50% year on year thanks to FAME II and PLI incentives. Electric three-wheelers, buses, and commercial vehicles increase volume. Every EV unit manufactured requires an OBC, making OBC manufacturing a high-volume business that is directly related to India’s EV growth trajectory.
The opportunity for import substitution is enormous, since a large portion of OBC components and assembled systems are currently imported from China and Taiwan. Domestic OBC manufacturers who can compete with Indian EV OEMs (Ola Electric, TVS, Hero Electric, Bajaj, Tata Motors EV) lower their supply chain risk—and the government’s. The desire for domestically built EV components promotes this trend.
Types of Onboard Chargers
- Single-phase OBC (3.3 kW): Standard for two-wheelers and small EVs—the most widely produced.
- Single-phase OBC (7.4 kW): For four-wheelers and premium EVs—faster AC charging.
- Three-phase OBC (11 kW/22 kW): High-power for commercial EVs and premium passenger vehicles.
- Bidirectional OBC (V2G/V2L capable): Enables vehicle-to-grid or vehicle-to-load power flow — premium developing category.
- Integrated OBC + DCDC Converter: Combined equipment that handles both battery charging and 12V auxiliary supply—space and cost efficient.
Project Cost for Onboard Charger Manufacturing
Component | Small Unit (₹) | Medium Unit (₹) |
PCB SMT assembly line | 3,00,000–6,00,000 | 7,00,000–15,00,000 |
Power component testing setup | 1,00,000–2,00,000 | 2,00,000–4,00,000 |
Enclosure fabrication tools | 80,000–1,50,000 | 1,50,000–3,00,000 |
Electronic components (MOSFETs, transformers, capacitors) 3 months | 3,00,000–6,00,000 | 6,00,000–12,00,000 |
BIS + AIS certification | 2,00,000–3,00,000 | 2,00,000–3,00,000 |
Work shed + working capital | 2,00,000–3,50,000 | 3,50,000–6,00,000 |
Total | ₹11.80–22 lakh | ₹22–43 lakh |
PMEGP: Up to ₹50 lakh → 15–35% capital subsidy.
What Our Report Covers OBC
- Product Range: Two-Wheeler Onboard Chargers, Three-Wheeler OBCs, Passenger EV Onboard Chargers, Commercial EV Charging Units, AC-DC Conversion Systems, and Smart Charging Modules.
- The manufacturing process involves PCB assembly, SMT mounting, power electronics integration, transformer and inductor assembly, enclosure fabrication, firmware programming, calibration and testing, thermal management integration, final assembly, and packaging.
- Raw material analysis for power semiconductors, PCBs, capacitors, transformers, inductors, connectors, cooling components, enclosures, and electronic components.
- Machinery and equipment include SMT lines, pick-and-place machines, reflow ovens, PCB testing equipment, calibration systems, quality inspection instruments, and assembly tools.
- Compliance and certification include AIS 048 requirements, automotive quality standards, the OEM qualification process, testing requirements, and EV industry compliance.
- Market Analysis: Electric Vehicle OEMs, Electric Two-Wheeler Manufacturers, Three-Wheeler Companies, Commercial EV Manufacturers, Component Suppliers, and Export Opportunities
Why Choose Sharda Associates
- 45,500+ project reports — including EV components, electronics manufacturing, PLI-linked projects
- AIS 048 compliance timeline correctly reflected — OEM qualification is a 3–6 month process post-certification
- 100% Bank-Ready Project Reports for MSME, EV Manufacturing, PLI programs, and Industrial Finance
- Detailed production and assembly process that includes PCB assembly, power electronics integration, testing, calibration, and final inspection.
- Accurate raw material costs for power semiconductors, transformers, capacitors, PCBs, connectors, cooling systems, and enclosures.
- Separate revenue projections for two-wheeler, three-wheeler, passenger EV, and commercial EV onboard charger segments
- Profitability analysis includes ROI, DSCR, break-even point, and cash flow estimates.
- Market demand assessment for EV OEMs, EV component suppliers, retrofit markets, and charging ecosystem members.
- Starting at ₹2,999 · 24–48 hours
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Frequently Asked Questions
An onboard charger manufacturing project report helps banks evaluate business feasibility, machinery requirements, compliance obligations, market demand, profitability, and repayment capacity. It is frequently required for MSME, EV manufacturing, and industrial finance applications prior to project funding approval.
AIS 048 compliance assures that onboard chargers fulfill automobile safety and performance requirements. EV manufacturers typically require approved products prior to supplier onboarding. Banks assess compliance deadlines since certification has a direct impact on market entrance, client acquisition, and revenue generation.
Typically, an onboard charger manufacturing unit requires SMT lines, PCB assembly equipment, testing systems, calibration instruments, power electronics assembly stations, quality inspection tools, and packaging. Proper machinery planning aids in developing realistic production and budgetary estimates.
After certification, EV producers perform supplier audits, product validation, reliability testing, and commercial evaluations. This qualifying procedure often takes three to six months before commercial orders are placed, making it an important feature in project planning and revenue projections.
The primary raw materials include power semiconductors, printed circuit boards, capacitors, transformers, inductors, connectors, cooling components, and metal enclosures. These components are combined and tested to provide automotive-grade onboard charging systems.
The company has enormous development potential due to rapid EV adoption and government support for electric mobility. Profitability is determined by technology capability, OEM relationships, production efficiency, certification status, and effective involvement in the rapidly developing EV supply chain.
A professionally written project report illustrates financial viability, compliance planning, machinery needs, market potential, and payback capability. It enables lenders to effectively assess project risk and increases approval chances for EV manufacturing and MSME financing schemes.
Banks may reject applications based on unrealistic sales predictions, missed certification deadlines, poor market analysis, improper machinery costing, or insufficient working capital planning. A detailed project report addresses these concerns while considerably strengthening the financing application.