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On-Board Charger Solutions from Vishay

The trend towards electrification in the automotive sector is gathering pace. This is accelerated not only by the limits for exhaust emission values, but also by subsidy programs. A core element of these vehicles is the battery charging system, also known as the on-board charger (OBC). With these systems, the battery can be charged at a standard household connection or at a commercial wallbox. Depending on the vehicle class, charging systems with up to 22 kW loading power can be installed. This high charging power is required for an acceptable charging time. The use of chargers in the vehicle places very high quality requirements on suppliers of electronic components. Vishay can draw on a wealth of experience in this area and offer a broad portfolio of suitable components.

OBCs of up to 22 kW (400 VAC input, 500 VDC output) rely on semiconductor solutions in power modules due to their high power density. By using modules specifically designed for the charger, it is possible to achieve high system efficiency and at the same time high power density. The EMIPAK 2B package is proving to be a very robust and efficient solution in this field. This package has already established itself in a wide variety of applications and configurations. The internal structure of the power modules is specially adapted to the applications and the requirements of the automotive industry. As a result, the power modules can be adapted to each generation of charging systems, and the latest generation of semiconductors can be used in each case. The use of press-fit connections for the electrical contacts makes it very easy and quick to assemble the modules. The direct connection to the liquid cooling system in the vehicle enables a very high power density and optimizes the thermal management of the modules.

Figure 1: EMIPAK 2B power module for on-board charger

In today’s electric vehicles, a high power OBC is required to charge the large capacity battery pack in a short period of time. 22 kW OBCs work with a 3-phase input voltage in the range of 340 VAC to 480 VAC and provide an output voltage range of 250 V to 500 V, with a maximum current of approximately 50 A. The input stage uses a T-type Vienna rectifier that meets the requirements for harmonic and reactive power, yet allows the charger to operate over a wide input voltage range. The output voltage is controlled by an isolated resonant converter with asynchronous rectification.

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