Neenjas Electric Develops 2.2kW Integrated EV Charger

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%. Compared with its off-board charger design, the integrated system reduces weight by 40%, volume by 30% and bill of materials (BOM) costs by 20%. The development was undertaken for Royal Enfield's Flying Flea electric motorcycle programme, which required a compact charging solution capable of fitting within a restricted, tank-shaped enclosure. The company has already deployed approximately 3,000 chargers for the programme.

Speaking at the Autocar Professional India EV Conclave 2026, Vineet Gupta, Managing Director and Chairman of Neenjas Electric, explained that the original requirement came from an OEM seeking a 2.2kW integrated OBC and DC-DC converter with efficiency exceeding 95% and weight below 3.5kg. The available packaging space presented a significant engineering constraint. To accommodate the system, Neenjas Electric developed a tapered, trapezoidal enclosure designed around the motorcycle's tank-shaped packaging requirements, achieving the specified performance objectives.

Single-Transformer Architecture

The integrated charger combines a totem-pole bridgeless power factor correction (PFC) stage, a dual active bridge (DAB) converter and a phase-shifted full-bridge DC-DC stage. A key feature is its single three-port transformer architecture, which replaces the separate transformers traditionally used for the OBC and DC-DC stages. Consolidating the magnetic components helps reduce system complexity and contributes to the overall reduction in weight, volume and component costs.

The system uses a single microcontroller to manage the PFC, DAB and DC-DC stages, alongside controller area network (CAN) communication. Its architecture was developed with software-defined vehicle requirements in mind, enabling configuration through software. Neenjas Electric has achieved a claimed efficiency of 96.5%, with the integrated unit weighing approximately 3.5kg. The company reports that the design is 40% lighter and 30% smaller than its off-board charger, while the shared transformer and microcontroller architecture contributes to a 20% reduction in BOM costs.

Manufacturing considerations have also influenced the design. Neenjas Electric has replaced conventional wiring arrangements with panel-mounted connections to simplify assembly. Integrating the OBC and DC-DC converter also enables both functions to be manufactured on a common assembly line instead of requiring separate production processes. This approach brings electrical integration and manufacturing simplification into the same development programme.

Gupta identified packaging space as a major obstacle to adopting on-board charging in electric motorcycles. The challenge also extends to electric three-wheelers, where operators sometimes carry bulky off-board chargers inside their vehicles because of concerns about finding suitable charging facilities during operation. Such chargers are not designed for permanent vehicle integration, and carrying additional equipment increases the vehicle's weight. Integrating charging functionality directly into the vehicle therefore addresses both packaging and equipment-carrying challenges.

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, with approximately 3,000 units already deployed. The charger has been designed to meet UN ECE R10 electromagnetic compatibility requirements for European markets. This provides the programme with an integrated charging solution developed around its specific packaging constraints and applicable electromagnetic compatibility requirements.

The company is also supplying a 3.3kW on-board charger to Raptee.HV. The electric motorcycle uses a 312V electrical architecture designed to support charging at compatible Combined Charging System (CCS) charging stations. Neenjas Electric's charger combines an analogue PFC stage with a digitally controlled LLC resonant converter. This configuration supports the charging requirements associated with the motorcycle's electrical architecture.

Gupta stated that the 3.3kW charger achieves a power-density figure of 26.42, which he described as higher than the industry standard. However, the unit of measurement was not specified during the presentation. According to the company, more than 40,000 units of this charger design have been deployed in the field. The figure represents the reported deployment of the charger design rather than a separately specified production target.

In addition to its electric motorcycle programmes, Neenjas Electric supplies a 0.9kW charger to Kinetic. Its electric three-wheeler business includes more than 28,000 on-board chargers supplied to Euler Motors and approximately 1,000 units delivered to another manufacturer identified during the presentation as Grivol. These programmes demonstrate the company's involvement across electric two-wheeler and three-wheeler charging applications, with products developed for different power and vehicle requirements.

6.6kW Bidirectional Platform Under Development

Neenjas Electric is developing a 6.6kW three-in-one power electronics platform that integrates an on-board charger, DC-DC converter and power distribution unit (PDU). The system is being designed with bidirectional power-flow capability, bringing three power electronics functions together within a single platform. The development represents an expansion of the company's product portfolio beyond its existing on-board and off-board charging solutions.

According to Gupta, the platform has reached the printed circuit board development stage, with start of production targeted for the first quarter of 2027. The stated timeline remains a production target rather than a confirmed production commencement. The integrated architecture is intended to combine charging, DC-DC conversion and power distribution functions, extending the company's development activities into more comprehensive vehicle power electronics systems.

Neenjas Electric 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 the company's products have been developed to meet applicable Indian and international automotive standards, including UN ECE R10 and AIS-004. These standards form part of the company's stated product development and validation framework across its charging portfolio.

In-House Design and Manufacturing

Neenjas Electric carries out product development internally, covering system requirements, schematic design, printed circuit board layout, embedded software, firmware and design validation. Its manufacturing infrastructure includes three surface-mount technology (SMT) lines, supported by in-house casting and wiring harness capabilities. This combination of engineering and manufacturing activities allows the company to manage product development and production processes within its own operations.

Gupta said the company develops its own products rather than relying on externally designed systems for assembly. This approach allows Neenjas Electric to work directly with vehicle manufacturers on packaging constraints, electrical specifications and product validation. The company's engineering involvement can therefore extend from initial system requirements through hardware and software development to manufacturing considerations, supporting the development of charging products around individual vehicle programmes.

The company is seeking closer collaboration with OEMs on customised charging systems for electric two-wheelers and three-wheelers. Gupta encouraged manufacturers to share packaging and performance requirements during the early stages of vehicle development. Early engagement would allow charger architecture, physical integration and validation activities to be undertaken jointly, rather than addressing packaging and system compatibility only after vehicle development has progressed.

Industry Impact & Outlook

Neenjas Electric's integrated charging developments highlight the importance of packaging, weight, cost and manufacturing efficiency in electric two-wheeler and three-wheeler power electronics. The 2.2kW programme demonstrates how combining the OBC and DC-DC converter can address restricted vehicle packaging requirements while reducing component count and simplifying assembly. Its reported deployments across multiple vehicle manufacturers also illustrate the company's existing participation in different EV segments. The proposed 6.6kW bidirectional platform, targeted for production in the first quarter of 2027, represents its next product development milestone. Closer collaboration with OEMs during early vehicle development remains central to the company's approach to customised charging solutions.

Frequently Asked Questions

What is the efficiency of Neenjas Electric's integrated 2.2kW charger?
Neenjas Electric's integrated 2.2kW on-board charger achieves a claimed efficiency of 96.5%, according to the company. Developed for an electric motorcycle application, the system combines an on-board charger and DC-DC converter in a single unit. It was designed to exceed the original requirement of 95% efficiency while keeping weight below 3.5kg. The finished system weighs approximately 3.5kg and also delivers reported reductions of 40% in weight, 30% in volume and 20% in BOM costs compared with the company's off-board charger design.

Which electric motorcycle programme uses Neenjas Electric's 2.2kW integrated charger?
The 2.2kW integrated charger has entered production for Royal Enfield's Flying Flea electric motorcycle programme, with approximately 3,000 units already deployed. The charger was developed to fit within a restricted, tank-shaped enclosure, requiring a customised tapered, trapezoidal design. Its specifications include a claimed efficiency of 96.5% and a weight of approximately 3.5kg. The system has also been designed to meet UN ECE R10 electromagnetic compatibility requirements for European markets, according to the company's presentation.

What technology does Neenjas Electric use in its integrated charger?
The integrated charger combines a totem-pole bridgeless power factor correction stage, a dual active bridge converter and a phase-shifted full-bridge DC-DC stage. Instead of using separate transformers for the on-board charger and DC-DC converter, Neenjas Electric has developed a single three-port transformer architecture. One microcontroller manages the PFC, DAB and DC-DC stages, along with CAN communication. The architecture reduces the number of magnetic components and supports the company's objectives of lowering system weight, volume and bill of materials costs.

Which other automotive companies receive chargers from Neenjas Electric?
Neenjas Electric supplies charging products to several automotive manufacturers, including Raptee.HV, Kinetic and Euler Motors, in addition to Royal Enfield. Its portfolio includes a 3.3kW on-board charger for Raptee.HV's 312V electric motorcycle architecture and a 0.9kW charger for Kinetic. In the electric three-wheeler segment, the company has supplied more than 28,000 on-board chargers to Euler Motors and approximately 1,000 units to another manufacturer identified as Grivol. More than 40,000 units of its 3.3kW charger design have also reportedly been deployed in the field.

What is Neenjas Electric's upcoming 6.6kW power electronics platform?
Neenjas Electric is developing a 6.6kW three-in-one power electronics platform that integrates an on-board charger, DC-DC converter and power distribution unit. The platform is being designed to support bidirectional power flow, combining three functions within a single system. According to Managing Director and Chairman Vineet Gupta, the development has reached the printed circuit board stage. The company is targeting the start of production in the first quarter of 2027. This development is intended to expand its portfolio beyond existing on-board and off-board charging products.

How many chargers has Neenjas Electric supplied cumulatively?
Neenjas Electric has supplied more than 200,000 chargers cumulatively, according to Managing Director and Chairman Vineet Gupta. This includes over 130,000 off-board chargers and more than 40,000 on-board chargers. Its reported deployments cover electric motorcycle and three-wheeler applications, with products supplied to multiple vehicle manufacturers. The company's manufacturing infrastructure includes three surface-mount technology lines, alongside in-house casting and wiring harness capabilities. Its product development activities also cover system requirements, schematic design, PCB layout, embedded software, firmware and design validation.