Power Electronics
On-board chargers for eMobility
NOVELIC offers on-board charger (OBC) solutions for electric vehicles, ranging from 6.6 kW to 11 kW applications. Our OBCs are efficient, three-phase designs based on SiC-MOSFET technology.
Fast Charging
Universal input with PFC operation
Three-phase solutions
Bidirectional operation for V2L and V2H modes
Customizable & expandable
Liquid & air cooling
72V / 6.6kW On-Board Charger for two wheelers and three wheelers
This on-board charger (OBC) is used to charge the battery in two- and three-wheelers from AC grid while the vehicle is parked. The development target is efficient power conversion for 72 V systems with increased power density and reliability.
Additionally, a bidirectional power flow feature is implemented to support V2L and V2H operation as needed.
The pictured board is a reference design. Any solution is customizable to the client’s needs.
Use Case – Hardware Platform
Designed on a single board featuring:
- Full SiC AC-DC converter, including
- input relay at each phase
- passive input EMC filter
- three-phase bidirectional PFC stage for universal input
- Full SiC DC-DC converter based on Dual-Active-Bridge with ferrite transformer for galvanic isolation
- Polypropylene film capacitors in DC circuits used to avoid issues related to use of electrolytic capacitors
- Separate power + measurement and control board
- Full galvanic isolation between power/measurement and control-board
- External water-cooling or forced-air cooling with integrated long-life fans
Use Case – SiC Power Stage
A full SiC-MOSFET power stage provides improved efficiency and smaller volume.
The application of top-side cooled compact semiconductor modules and transistors offers additional advantages:
- Lower board space
- Lower losses due to paralleling transistors on high-current side of DC-DC converter
- Top-side cooling for easier and cost-effective assembly of heatsinks
- Separate power + measurement and control board
- Better integration of switches for decreased stress and EMI issues
All gate-driver ciruits are galvanically isolated and provide a high CMI immunity level.
Use Case – Control section
Each converter is controlled by a dedicated 32-bit high-performance microcontroller designed for digital power conversion:
- Wide range output voltage regulation and accurate charge current control
- High-precision measurement and control
- Floating point unit with math accelerators support for quick and efficient execution of demanding control algorithms
- High-resolution PWM timers for precise generation of driving signals
- Main communication with vehicle control system using a CAN interface
- Wide-range of additional communication capabilities
Customization
| Design | Single-board, or modular – for space-saving designs. For lower power outputs, single phase is also available |
| Cooling | forced-air or liquid |
| Stacking | possible, to increase the output power level |
11 kW On-Board Charger
The EV on-board charger (OBC) recharges the high-voltage (HV) main battery from AC grids while the car is parked. Typical development targets are efficient power conversion for 400 V and 800 V systems, power density, reliability, and bi-directional powerflow to enable V2L, V2H, and V2G.
The pictured board is a reference design. Any solution is customizable to the client’s needs.
Use Case – Hardware Platform
Designed on a single board featuring:
- Input relay at each phase
- Passive input EMC filter
- Three-phase bidirectional PFC stage for universal input
- Dual-active-bridge with ferrite transformer for galvanic isolation
- Polypropylene film capacitors used to avoid aging and thermal issues with electrolytic capacitors
- Separate power + measurement and control board
- Full galvanic isolation between power/measurement and control-board
- Forced-air cooling with long-life fans
Use Case – SiC Power Stage
A full SiC-MOSFET power stage provides improved efficiency and smaller volume.
The usage of compact semiconductor modules offers additional advantages:
- Lower board space
- In-line positioning for better utilization of heat-sinks
- Top-side cooling for easier and cost-effective assembly
- Separate power + measurement and control board
- Better integration of switches for decreased stress and EMI issues
All gate-driver ciruits are galvanically isolated and provide a high CMI immunity level.
Use Case – Control section
Each converter is controlled by a dedicated 32-bit high-performance microcontroller designed for digital power conversion:
- Wide range output voltage regulation and accurate charge current control
- High-precision measurement and control
- Floating point unit with math accelerators support for quick and efficient execution of demanding control algorithms
- High-resolution PWM timers for precise generation of driving signals
- Main communication with vehicle control system using a CAN interface
- Wide-range of additional communication capabilities
Customization
| Battery voltage | 400V or 800V |
| Power level | 6.6kW, 11kW, or 22kW |
| Design | single-board, or modular – for space-saving designs |
| Cooling | forced-air or liquid |
| Stacking | possible, to increase the output power level |