(H)EV on-board battery charger - hybrid / electric vehicle

Overview

Designing systems with a wide range of I/O voltages - modular concept enables 1 to 3-phase AC power supply

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:

Products

(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:

PFC stage

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 

boost_topology

Advantages:

  • Fits all required power classes  from 3.6 kW up to 7.2 kW
  • Cost-optimized solution (limited No of power semiconductors)
  • Simple implementation

Disadvantages:

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

Recommended products for

totem_pole_topology

Advantages:

  • Fits all required power classes  from 3.6 kW up to 11 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

LLC topology

Advantages:

  • Fits all required power classes from 3.6 kW up to 11 kW
  • Widely used in industrial and consumer applications
  • No choke at the output required to filter ripple
  • Simple upgrade for bidirectional

 

Recommended products for

ZVS topology

Advantages:

  • Fits all required power classes up to 3.6 kW
  • Widely used in industrial and consumer applications
  • No choke at the output required to filter ripple
  • Simple upgrade for bidirectional

 

Recommended products for

Your OBC and HVDCDC  development also need thermal management. Pumps and fans are the key functions. Sensors and control units are required to manage the functions. 

Infineon offers different system solutions to overcome these challenges and meet customer-specific preferences. Infineon´s extensive offering of intelligent motor control ICs is complemented by microcontrollers, sensors, transceivers, voltage regulators, and MOSFETs to simplify the design of end-to-end system solutions and different integration levels are offered based on different customer needs. Integrated system on chip solutions, known as Embedded Power ICs, can deliver a best-fit set of functions to address these applications, especially for 12V.

48V systems support motor control pumps and fans, up to 1 kW, and other motor control applications with high power density and/or continuous use.

Connectivity and HMI for Charging

Charging Connectivity is an integral part of our emission-free future, connecting the vehicle to the power grid for an efficient and optimized electricity distribution.

Charging the Electric Vehicle (EV) does require communication between the vehicle, the charging unit and the power grid. Possibly even connecting the vehicle to the smart home for even more comfort. Especially with bi-directional charging upcoming, this communication will require an even deeper interaction within the vehicle as well as with the consumer and energy provider. The current state of the battery, the user, or smart home requirements need to be aligned to the available energy source and the energy provider, possibly including automated billing features. 

Communication standards for this purpose are defined in the ISO15118. With Infineon's expertise and broad product portfolio we enable our customers to develop solutions that are enabling the ISO15118 defined requirements and beyond. The TPM module in combination with the AURIX MicroController family allows secured communication, the WiFi/BT module complements the power line communication and with attached memory data can be locally stored and updated related, the connection to the vehicle network is achieved with the CAN transceiver. This, just to name some of the key elements for developing a Charging Connectivity module.

Learn more about our products 

Memories for automotive

WiFi/BLE combo controllers

Wi-Fi and Bluetooth components for Telematic control units

OPTIGA™ TPM SLI 9670

Traveo™ II CYT2B9 series

Microcontroller

Security controller

Automotive security systems

HV LV DCDC

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