Hybrid SUV Project in Europe With Our 800V OBC & DC/DC Converter Combo
Project Overview
As the automotive industry continues to evolve, the demand for innovative charging solutions is on the rise. In 2022, a European automotive company approached us for an 800V high-voltage onboard charger (OBC) to power their hybrid SUV project. They were in search of a reliable solution that could meet the unique requirements of their vehicle platform.
The Shift to 800V EV Cars
With electric vehicle (EV) adoption expected to grow rapidly in the coming years, the next generation of EVs needs to offer longer range, faster charging, and higher power output to fully replace traditional gasoline-powered cars. To achieve these goals, EV battery systems require higher voltage configurations. This is why the shift from 400V to 800V platforms in the EV market has become inevitable.
There are currently two main approaches to implementing an 800V platform for hybrid cars:
- Partial 800V Platform: This method retains some 400V components, such as air conditioning and DC/DC converters, while upgrading only specific high-voltage parts to 800V.
- Full 800V High-Voltage System: All high-voltage components, from the battery to the drivetrain (including the inverter, onboard power control unit, air conditioning compressor, and thermal management system), are designed with an 800V architecture. This approach significantly improves charging efficiency, speed, and overall system energy performance.
However, for automotive manufacturers, finding suitable EV systems that support the 800V high-voltage platform with high product quality and reliable performance is challenging. As a result, sourcing the right solutions becomes crucial and can require additional time and costs.
How We Worked
Despite extensive market research, the client had difficulty finding a reliable solution that matched the 800V high-voltage requirements for their hybrid SUV. When they reached out to us, we were able to offer them the solution from out range of EV onboard chargers and converters, which span from 3.3 kW to 40 kW, with high-voltage and V2X options.
After reviewing their specifications, we proposed an OBC and DC/DC converter system designed for 800V EV cars that perfectly matched their needs. They quickly ordered samples for testing, and the results exceeded their expectations. Our system’s compact, lightweight design and high performance amazed the client.
Result
The client was so impressed with the results that they placed an additional order for 25 more units and signed a contract with us to begin preparing for mass production of their hybrid SUVs within 2 years. In total, they have ordered 30 units for the initial testing, with plans to order over 500 units for the first phase of production. These hybrid SUVs are set to lead the market with the latest automotive high-voltage system technology.
System in This Project
10 kW Onboard Charger & DC/DC Converter Combo
- Dimension: 310*219*111 mm (connectors excluded)
- Weight: 9.2 kg
- Input voltage range: 90-264 VAC@1φ; 185-456 VAC@3φ
- Rated input voltage: 230 VAC@1φ; 380 VAC@3φ
- Input frequency range: 45-65 Hz
- Input current: 32 A max.@1φ; 16 A max.@3φ
- Output voltage range: 350-800 VDC
- Max. output current: 13.8 A@1φ; 20.3A@3φ
- Output power: 6.6 kW max. @1φ; 9.6 kW max.@3φ
- Efficiency: ≥94@rated load; ≥95@half load
- Input voltage range: 350-800 VDC
- Input current: 11 A max.
- Output voltage: 220 VAC (±5%)@1φ
- Output voltage frequency: 50 Hz (±1%)
- Rated output power: 3.3 kVA
- Output efficiency: 93%
- Input voltage range: 350-800 VDC
- Output voltage range: 11-16 VDC
- Rated output voltage: 14 VDC
- Output current: 215 A continuous
- Output power: 3 kW continuous
Contact Info
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