Benefits and the passive component of on-board chargers

Benefits of on-board charger
The main benefit of on-board charger is that it uses off-the-shelf AC power, and through a lead, the car can be plugged into any of the billions of outlets installed in each building.
Level 1 AC charging uses single-phase power, which is about 1.9kW for 120V power supply and 3.7kW for 220V-240V power supply. This is the most common form of charging in private homes.
However, businesses typically use three-phase power for charging, which can increase the available power of on-board charger to about 20kW, which is much faster than first-stage charging.
AC charging is the most flexible, as there are charging stations that can provide the full range of charging needs depending on the user's lifestyle and vehicle usage. If the vehicle is only used for daytime commuting, charging at night is very convenient. AC charging is not ideal for extended charging because it takes too long to charge and requires more distance than the vehicle can travel.
The passive component of an on-board charger
Passive devices such as magnetic elements and capacitors play a key role in all aspects of an on-board charger. The boost converter forming the front end of the PFC stage will consist of a common-mode EMC filter, filter capacitors, PFC coils, and a DC link capacitor that provides charge storage between the boost stage and the on-board charger.
LLC converters are widely used in industrial and consumer applications. Although no specific output choke is used, the magnetic elements are used for isolating transformers and output EMC filters, as well as various capacitors.

The potential for adopting wireless charging has led to a broader need for passive components, including coils for power transmission (sending and receiving), as shown on the right, and proximity detectors to ensure the vehicle is properly aligned with the charger.
Although many recent advances have focused on power electronics semiconductor devices such as MOSFET and IGBT and their related controls, few of these are able to realize their potential in passive components without a corresponding increase in the performance they rely on as well as connectors and cables.
In many applications, multiple resistors are used in parallel simply to handle the required power loss. While this provides a solution at the circuit level, it increases the number of components, the cost, and the required board space -- none of which is ideal in an automotive environment. A recent innovation was the first high-power resistor offered with the AEC-Q200 qualification (left). These 1% tolerance devices are supplied in an insulated package designed to be mounted directly to the radiator, where they are rated up to 800W. This high power dissipation allows multiple low-power devices to be replaced by a single resistor, or (due to its pulsing capacity) a larger wire-wound resistor can be replaced, saving board space.
An inductor is a component that, if not carefully selected, may be damaged by prolonged exposure to heat and vibration. However, rugged models that meet AEC-Q200 standards, such as metal composite power chokes for boost and buck operation and filtration. The latest versions offer high vibration resistance and are capable of operating at temperatures up to 150°C (including self-heating) while maintaining excellent inductance stability over this extended temperature range. The shielding structure virtually eliminates flux leakage, thus minimizing any electromagnetic interference problems.
EV on-board charger supplier
Grasen on-board charger is mainly used for hybrid vehicles, pure electric vehicles, electric buses, electric logistics vehicles and other new energy vehicles, and is suitable for charging lithium iron phosphate, lithium manganese acid, lead acid and other vehicle power batteries. Start your EV charging station businesses with Grasen.
For a no-obligation quote latest price of on-board charger or technical support, please contact us and fill in your details, and we’ll get back to you within 24 hours.
 
 

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