4-in-1 PDU

Integrated Power Management System for Electric Vehicles: Product Overview

Product Architecture
The Integrated Power Management System (IPMS) for electric vehicles (EVs) comprises four core modules—CCU Control Module, DC/DC Converter, DC/AC Inverter, and PDU—that work synergistically to ensure efficient, reliable, and safe power distribution. Below is a detailed breakdown of each component’s functionality and their collaborative operation:

1. CCU Control Module (Central Control Unit)

Function:
Acts as the system’s “brain,” overseeing control logic, signal processing, and fault diagnostics.

• Monitors real-time status of vehicle components (e.g., battery voltage, motor temperature).
• Executes control algorithms for power allocation and system protection.
• Interfaces with vehicle CAN bus for communication with ECUs (Engine Control Units).

Key Features:

• Microprocessor-based architecture with embedded firmware.
• Supports over-the-air (OTA) updates for functional expansion.

2. DC/DC Converter Module

Function:
Converts high-voltage DC (300–800V) from the battery pack to low-voltage DC (12V/24V) for auxiliary systems.

• Powers lighting, infotainment, and control circuits.
• Maintains voltage stability during dynamic load changes.

Key Features:

• Bidirectional conversion capability (charging/discharging).
• Galvanic isolation between high-voltage and low-voltage circuits.

3. DC/AC Inverter Module

Function:
Converts DC power to AC power for high-voltage motors and accessories.

• Drives traction motors, air conditioning compressors, and hydraulic pumps.
• Enables regenerative braking by converting AC back to DC.

Key Features:

• High-frequency switching (20–50 kHz) for compact design.
• Sinusoidal PWM output for motor efficiency >95%.

4. PDU (Power Distribution Unit)

Function:
Manages high-voltage distribution and safety.

• Controls charging/discharging pathways.
• Provides overload/short-circuit protection.
• Monitors high-voltage insulation and temperature.

Key Features:

• IP67-rated enclosure for harsh environments.
• Integrated pre-charge circuit to limit inrush current.

Synergistic Operation

1. CCU Coordination:
   The CCU analyzes input from sensors and vehicle commands, then issues instructions to the DC/DC, DC/AC, and PDU modules to optimize power flow.
2. Voltage Conversion:
   • DC/DC ensures low-voltage systems receive stable power.
   • DC/AC supplies variable AC power to motors based on driving conditions.
3. PDU Safety Net:
   The PDU dynamically adjusts power routes while safeguarding against faults, ensuring compliance with ISO 26262 functional safety standards.

Technical Advantages

• Compact Integration: Reduces wiring complexity by 40% vs. discrete systems.
• Efficiency: >98% combined conversion efficiency (DC/DC + DC/AC).
• Scalability: Modular design适配 48V mild hybrids to 800V full EVs.

Applications

• Passenger EVs (BEVs/PHEVs)
• Commercial EVs (buses, delivery vans)
• Off-road machinery (mining trucks, forklifts)

Custom solutions available for extreme temperature (-40°C to +125°C) and high-vibration environments.

Model	NB100-D-055-01 5-PC	NB100/101-D-150-030	NB100-D-075-020	NB100-D-015-PDU	NB100-PDU-2DA-040-D-060
Name	4-in-1 Intelligent Control System	Sync/Async Combined Drive Controller	2-in-1 Drive Controller	PDU + DCDC	Auxiliary 4-in-1 Drive Controller
Inverter Power	5.5KW	15KW	7.5KW	/	5KW + 5KW
DC/DC Power	1.5KW	3KW	2KW	1.5kW	6KW
Heating PTC Power	24KW	/	/	12KW	/
CCU Control	Integrated	/	/	/	/
Cooling Method	Natural Cooling	Air Cooling	Air Cooling	Natural Cooling	Liquid Cooling
Protection Rating	IP67	IP65	IP65	IP67	IP67
Communication	CAN Bus	CAN Bus	CAN Bus	CAN Bus	CAN Bus
Dimensions (mm)	415×240×117	349×340×158	362×263×144	290×205×138	581×406×221
Applications	Energy Storage, Water-Cooled Units	Electric Bus	Electric Bus/Cold Chain	Water-Cooled Units	Hydrogen Heavy-Duty Truck