DC/DC Converter for Electric Vehicles: Product Overview

Introduction
In electric vehicles (EVs), the high-voltage battery pack stores direct current (DC) energy unsuitable for powering low-voltage systems (e.g., lighting, infotainment, instrumentation). The DC/DC converter bridges this gap by efficiently stepping down high-voltage DC (typically 300-800V) to 12V DC, ensuring reliable power supply for auxiliary systems while maintaining compatibility with traditional automotive electrical architectures.

Key Functions & Features

  1. Voltage Conversion & Regulation
    • Converts high-voltage DC to stable 12V DC for low-voltage components.
    • Dynamically adjusts output based on load demands and battery state-of-charge.
  2. Integration Flexibility
    • Standalone unit or integrated into Power Distribution Units (PDU) or Power Electronics Units (PEU).
    • Supports natural cooling or liquid cooling for thermal management.
  3. Safety & Protection Mechanisms
    • Electrical Protection: Overvoltage, undervoltage, overload, and short-circuit safeguards.
    • Thermal Management: Overtemperature shutdown and automatic recovery.
    • Isolation Design: Galvanic isolation between high-voltage and low-voltage circuits for enhanced safety.
  4. Smart Communication
    • CAN bus interface for real-time data exchange with Vehicle Control Units (VCUs).
    • Diagnostic capabilities for fault detection and status monitoring.

Technical Architecture

  1. Input Stage
    • High-voltage filtering circuits to suppress electromagnetic interference (EMI).
    • Full-bridge inverter for converting DC to high-frequency AC.
  2. Transformer & Rectification
    • Isolation transformer for voltage step-down and galvanic separation.
    • Synchronous rectification for efficient AC-to-DC conversion.
  3. Output Stage
    • LC filtering to stabilize output voltage.
    • SBC (System Basis Chip) module for auxiliary power supply to control circuits.
  4. Control & Protection
    • Microcontroller-based monitoring of voltage, current, and temperature.
    • PWM (Pulse Width Modulation) drive for power semiconductors.
    • Reverse polarity protection and input undervoltage lockout.

Advantages

  • Compact Design: Space-efficient layout for EV chassis integration.
  • High Reliability: Compliant with automotive grade standards (AEC-Q100).
  • Low Noise: Advanced EMI filtering for minimal electrical interference.

Applications

  • Battery Electric Vehicles (BEVs)
  • Hybrid Electric Vehicles (HEVs)
  • Commercial EVs (buses, logistics trucks)
  • Off-road electric machinery
DC – DC Power converter
Technical Data
Input voltage: 185V~850V (customized)
Power: 1.2KW/2KW/3KW
Static Battery Leakage Current: ≤10mA
Input control: hardware enable control, CAN communication
LV cable, withstand voltage 700~400Vdc
Rated output voltage: 27.5 ± 0.2Vdc, Max output current: 110A
Output voltage start time: within 6s (at rated load) (Input 540Vdc, output 27.5Vdc, rated load test time)
Output power: 3000W (MAX)
Static loss Current ≤10mA
Operation temperature: – 40°C – 65°C
Insulation resistance ≥20MΩ/100Vdc
Protection level: IP67
Cable requirements – HV cable, withstand voltage 1500Vdc;
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