POWER
can reduce OBC volume by up to 50 per cent compared with an equivalent two-stage design, simplifying the packaging of higher- power charging systems.
Higher system effi ciency Removing the intermediate DC bus can increase total system effi ciency by up to two per cent. Wide-bandgap devices enable zero- voltage switching across a broad operating range, while fewer semiconductor devices and lower RMS currents reduce conduction losses.
Lower BOM cost
Although wide-bandgap semiconductors have a higher upfront cost, fewer passive components and power devices can offset much of this premium. A single thermal loop simplifi es cooling, while fewer PCB layers and assembly operations streamline manufacturing.
Enhanced reliability
Single-stage designs avoid the large electrolytic DC-link capacitors that can limit the lifespan of two-stage OBCs, using longer-life fi lm capacitors or, in some matrix converter topologies, eliminating the DC-link capacitor entirely. These changes improve reliability and resilience at operating
temperatures of up to 125°C.
Current challenges and future outlook
Single-stage converters are not without challenges. Higher switching frequencies and single-stage conversion make electromagnetic interference more diffi cult to manage, requiring sophisticated fi ltering to meet automotive EMC standards. Calibrating controllers across wide input and output voltage ranges also requires advanced control algorithms and signifi cant engineering resources.
These challenges are being addressed through intelligent algorithms that optimise
modulation strategies in real time, simplifying tuning and improving performance. The co- design of transformers and inductors is also helping reduce size and electromagnetic interference, while increasing SiC and GaN production is gradually narrowing the cost premium associated with wide-bandgap devices.
The single-stage OBC DC/DC converter represents the next frontier in EV charging technology. By combining PFC and isolated DC/DC conversion in a single stage, it addresses the size, effi ciency and cost limitations of traditional two-stage designs while enabling capabilities such as bidirectional V2X functionality.
E
NGINEERS LECTRONICS FOR
Is your product or service getting worldwide exposure?
In addition to the regular users of EFE we get 7,500 new users each year across the globe from Japan to the USA, from China to Germany and many more
Want to be part of the action? Then contact: Jordan Tait | 01622 699 139 |
jtait@datateam.co.uk
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