Neenjas Electric has developed a 2.2kW integrated on-board charger (OBC) and DC-DC converter for electric motorcycles, achieving a claimed efficiency of 96.5% while reducing weight by 40%, volume by 30% and bill of materials (BOM) costs by 20% compared with its off-board charger design.
Speaking at the Autocar Professional India EV Conclave 2026, Vineet Gupta, Managing Director and Chairman of Neenjas Electric, said the system was developed for Royal Enfield's Flying Flea electric motorcycle programme, which required the charger to fit within a restricted, tank-shaped enclosure. The company has already deployed approximately 3,000 chargers for the programme.
"We got a problem statement from one of the OEMs to develop an EV charger which has to fit inside their tank," Gupta said. The requirement was for a 2.2kW integrated OBC and DC-DC converter with efficiency exceeding 95% and weight below 3.5kg. Neenjas Electric developed a tapered, trapezoidal enclosure to accommodate the system within the available space.
Single-Transformer Architecture
The integrated charger uses a totem-pole bridgeless power factor correction (PFC) stage, a dual active bridge (DAB) converter and a phase-shifted full-bridge DC-DC stage. Instead of using separate transformers for the OBC and DC-DC stages, the company developed a single three-port transformer architecture to reduce the number of magnetic components.
A single microcontroller manages the PFC, DAB and DC-DC stages, along with CAN communication. Gupta said the design was developed with software-defined vehicle requirements in mind, allowing configuration through software.
The company achieved 96.5% efficiency and a weight of approximately 3.5kg. Gupta said the integrated design is 40% lighter and 30% smaller than its off-board charger, while the use of a common transformer and microcontroller has reduced BOM costs by 20%.
The company has also replaced conventional wiring arrangements with panel-mounted connections to simplify assembly. Integrating the OBC and DC-DC converter allows both functions to be manufactured on a common assembly line rather than requiring separate production processes.
For electric motorcycles, Gupta identified packaging space as a major challenge in adopting on-board charging. In electric three-wheelers, he said operators sometimes carry bulky off-board chargers inside their vehicles because of concerns about finding charging facilities during operation.
"That off-board charger is not designed to put inside the vehicle because the off-board charger is a little bulky," Gupta said. Carrying additional equipment also adds weight to the vehicle.
Supplies to Royal Enfield, Raptee.HV and Euler Motors
Neenjas Electric's 2.2kW integrated charger has entered production for Royal Enfield's Flying Flea electric motorcycle programme. Gupta said approximately 3,000 units have already been deployed, with the charger designed to meet UN ECE R10 electromagnetic compatibility requirements for European markets.
The company is also supplying a 3.3kW on-board charger to Raptee.HV, whose electric motorcycle uses a 312V electrical architecture designed to support charging at compatible CCS charging stations. The charger combines an analogue PFC stage with a digitally controlled LLC resonant converter.
Gupta said the 3.3kW charger achieves a power-density figure of 26.42, which he described as higher than the industry standard. The unit of measurement was not specified during the presentation. More than 40,000 units of the charger design have been deployed in the field, according to the company.
Neenjas Electric is also supplying a 0.9kW charger to Kinetic. In the electric three-wheeler segment, it has supplied more than 28,000 on-board chargers to Euler Motors and approximately 1,000 units to another manufacturer identified during the presentation as Grivol.
6.6kW Bidirectional Platform Under Development
Neenjas Electric is developing a 6.6kW three-in-one power electronics platform integrating an on-board charger, DC-DC converter and power distribution unit (PDU). The system is being designed with bidirectional power-flow capability.
Gupta said the platform had reached the printed circuit board development stage, with start of production targeted for the first quarter of 2027. The new system will expand the company's portfolio beyond its existing on-board and off-board charging products.
The company has supplied more than 200,000 chargers cumulatively, including over 130,000 off-board chargers and more than 40,000 on-board chargers. Gupta said its products have been developed to meet applicable Indian and international automotive standards, including UN ECE R10 and AIS-004.
In-House Design and Manufacturing
Neenjas Electric undertakes product development internally, covering system requirements, schematic design, PCB layout, embedded software, firmware and design validation. Its manufacturing operations include three surface-mount technology (SMT) lines, along with in-house casting and wiring harness capabilities.
Gupta said the company develops its own products rather than relying on externally designed systems for assembly. This allows it to work directly with vehicle manufacturers on packaging requirements, electrical specifications and product validation.
The company is seeking closer collaboration with OEMs on customised charging systems for electric two-wheelers and three-wheelers. Gupta invited manufacturers to share their packaging and performance requirements early in vehicle development so that charger design and validation can be undertaken jointly.