Silicon carbide advancements and optimised inverter, On-Board charger designs with easy-to-integrate, high-performance, and compact components are key for leading in high-power applications. Simon Goodwin, in conversation with EFY’s Akanksha Sondhi Gaur and Nijhum Rudra at Electronica India, revealed that their newest reference designs offer the perfect toolkit for engineers, bridging the gap between concept and product.
Q. Could you expand on the components used in the OBC design and their importance?
A. The 11kW OBC design incorporates several critical components, including power factor correction (PFC) inductors, transformers, and filters. The power modules are designed to integrate closely with cooling systems, crucial for efficient heat dissipation in power electronics. With just two screws and a press-fit mechanism, our module simplifies the integration process for high-power solutions thereby reducing complexity. This is particularly important for the reliability of applications such as electric vehicle (EV) chargers. These customisable components offer flexibility for specific customer requirements while ensuring efficient charging and power density in EV systems.
Q. Can you explain the role of the 48V, 3.6kW LEV OBC for smaller EVs?
A. The 48V, 3.6kW OBC is designed explicitly for light electric vehicles (LEVs), such as e-scooters and small urban EVs. This design meets the lower power requirements of these vehicles while delivering fast, efficient charging. It prioritises compactness and ease of integration, critical for lightweight vehicles with limited space. Despite its smaller size, the charger still achieves high power density and efficiency, making it an optimal solution for LEVs.
Q. How do these designs benefit manufacturers, particularly in the EV industry?
A. The designs simplify the development process for manufacturers by integrating components such as magnetics and cooling systems into a cohesive design. The 11kW OBC reduces complexity by offering a press-fit system, allowing easy connection to heatsinks. This streamlines the assembly process and enhances system reliability. Customisable modules help manufacturers adapt the design to specific needs, providing a flexible, user-friendly solution.
Q. How are challenges like faster charging times addressed?
A. The 11kW OBC is tailored for high-power, high-voltage applications, addressing the demand for faster charging in EVs. It is optimised for 400V systems and supports many vehicles, from small cars to larger EVs. By pushing up to 3.6kW, our design enables faster charging for LEVs without needing specialised infrastructure, making it ideal for standard AC power grids.
Q. Explain how the DC/DC converter or inverter solves challenges for LEVs.
A. The 48V/12V bidirectional DC-DC converter and 48V, 10kW inverter are crucial components for hybrid and LEVs. The converter facilitates efficient power conversion between high and low-voltage systems, vital for energy recovery and powering low-voltage components, while the inverter, designed for compact LEVs, handles high currents and maximises both power density and efficiency. Additionally, the inverter is optimised for lightweight, cost-effective design, enhancing battery life and driving range and minimising heat dissipation, which is essential for the performance of small EVs.
Q. How does the DC-DC converter contribute to the larger EV ecosystem?
A. It plays a key role in interconnecting different voltage systems within a vehicle, such as transferring power from a 48V battery system to 12V loads. It also captures regenerative braking energy, improving overall energy efficiency in the vehicle. This is critical for supporting hybrid and EV architectures.
Q. Could you elaborate on how these designs improve EV performance?
A. The designs focus on enhancing power density, thermal management, and efficiency. For instance, the inverter design utilises reverse-package metal-oxide-semiconductor field-effect transistors (MOSFET) to reduce power losses and enable faster switching speeds. This results in more power in a smaller footprint, improving EV performance by extending driving ranges and reducing charging times.
Q. What role do components like resistors and MOSFETs play in passive and active discharge systems?
A. In high-voltage systems like those used in EV, discharge systems are essential for safety. Our resistors and MOSFETs are used in passive and active discharge systems to manage the release of stored energy from high-voltage capacitors safely. Passive discharge systems gradually bleed off charge, while active systems use MOSFETs for faster, controlled discharges, which are crucial during events like crashes. Both systems comply with strict automotive safety standards.
Q. Could you explain the high-voltage battery system with CAN FD’s role in EV communication?
A. The HV-IBSS-CANFD system facilitates communication within high-voltage battery systems in EVs. CAN FD (controller area network with flexible data-rate) supports faster data transmission, which enhances responsiveness and reliability, particularly in safety-critical applications like battery management.
Q. How does the eFUSE-48V 100A contribute to safety in 48V systems?
A. The eFUSE-48V 100A provides fast, programmable overcurrent protection, ensuring real-time monitoring and response to overcurrent conditions. Unlike traditional fuses, the eFUSE can be reset and reconfigured without replacement, offering enhanced protection and convenience in high-power applications.
Q. What differentiates your reference designs, and can your modules be customised for various charging systems or power needs?
A. The modules are highly customisable, allowing manufacturers to adjust specs to fit their needs. We offer standard designs but also work with customers to adapt for specific applications, including charging systems and power requirements. Customers handle final integration, such as housing and packaging. The flexible designs, including the compact MacPack module and advanced MOSFETs, deliver superior performance, power density, and size reduction over competitors.
