(H)EV – Batterieladeeinrichtung

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Find recommended ICs for your topology, reference designs, boards and design resources for electric drive train systems at full torque and with increased range

The on-board charger (OBC) is the system built into the car to recharge the high voltage battery from the AC grid while the vehicle is parking. Higher driving ranges of the plug-in hybrid (PHEV) and battery electric (BEV) vehicles are realized by increasing the battery capacity and the energy efficiency of the electric components. The used battery voltage classes tend to become standardized at approx. 450 V with a trend towards higher voltages, as this supports faster charging times and enables lighter cabling within the vehicle. Discrete high voltage components are widely used for OBC (on-board charger) applications, as price pressure increasingly displaces module-based solutions. The trend towards fast charging also impacts on the power range demanded from OBC topologies, therefore new designs trend towards 11 kW or even up to 22 kW. This development, paired with a demand for high efficiency and power density at low system cost, is a strong driver for the usage of three-phase solutions. Today typically there is a unidirectional power flow from the grid to the battery, but there is also bidirectional use cased like a battery to load or battery to grid.

Check the block diagram for the recommended products:

Produkte

(H)EV - on-board battery charger system diagram

System benefits

  • Suitable for plug-in hybrid and EV
  • Integrated Power Factor Correction (PFC)
  • Galvanic isolation
  • Wide range of input and output voltages
  • Adjustable current limits
  • Automotive standard communication (CAN)
  • Modular concept enables 1 to 3-phase AC power supply

Check the example of the 3-phase on-board charger:

3-phase onboard charger

    • 3-phase on-board charger

      Microcontroller

      Microcontroller: AURIX™ automotive microcontrollers TC2xxx or TC3xx

      tricore

    • 3-phase on-board charger

      Communication and system power management

      Communication and system power management: OPTIREG™ LDO combined with CAN transceivers or integrated solutions like System Basis Chips (SBC)

      Can

    • 3-phase on-board charger

      PFC power switches

      PFC power switches: CoolMOS™ Automotive MOSFET or CoolSiC™ Silicon Carbide Automotive MOSFET or TRENCHSTOP™ 5 Automotive IGBTs

      IGBT discretes

    • 3-phase on-board charger

      DC-DC primary power switches

      DC-DC primary power switches: CoolMOS™ Automotive MOSFET or CoolSiC™ Silicon Carbide Automotive MOSFET

      sic mosfet

    • 3-phase on-board charger

      DC-DC secondary power switches

      DC-DC secondary power switches: CoolMOS™ Automotive MOSFET or CoolSiC™ Silicon Carbide Automotive MOSFET and CoolSiC™ Automotive Schottky diodes

      Schottky diodes

    • 3-phase on-board charger

      Automotive Level Shifter ICs

      Automotive Level Shifter ICs and XENSIV™ Current Sensors

      1edn

    PFC stage:

    • Correction> 0,9
    • DC link voltage regulation
    • EMC input filter
    • Isolation to ground

    —> typically realized via standard boost topology or totem pole topology

    HV-HV DC-DC converter:

    • OBC output voltage regulation
    • Setting charge current
    • Galvanic isolation
    • EMC output filter

    —> typically realized via LLC topology or ZVS phase-shift topology (zero voltage switching)

    Advantages:

    • Fits all required power classes  from 2.3 kW up to 22 kW
    • Cost-optimized solution (limited No of power semiconductors)
    • Simple implementation

    Disadvantages:

    • Less efficiency (losses in rectifier)
    • Bidirectional implementation not possible

    Recommended products for

    Advantages:

    • Fits all required power classes  from 2.3 kW up to 22 kW

    • Higher efficiency when using active rectification

    • Can be easily upgraded for bidirectional charging 

    Disadvantages:

    • Higher costs (higher number of components)

    • More Complex implementation

    • Customers less experienced in the control of fast switching IGBTs

    Recommended products for

    Advantages:

    • Fits all required power classes from 2.3 kW up to 22kW
    • Widely used in industrial and consumer applications
    • No choke at the output required to filter ripple
    • Simple upgrade for bidirectional

    Disadvantages:

    • Complex control algorithm
      • Control needs to respect resonant frequency exactly
      • Failure in control results in damage of OBC
    • Requires constant input voltage

    Recommended products for

    Advantages:

    • Fits all required power classes from 2.3 kW up to 22kW
    • Widely used in industrial and consumer applications
    • No choke at the output required to filter ripple
    • Simple upgrade for bidirectional

    Disadvantages:

    • Complex control algorithm
      • Control needs to respect resonant frequency exactly
      • Failure in control results in damage of OBC
    • Requires constant input voltage

    Recommended products for

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