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Combining on-board charger, DC-to-DC converter and power distribution unit (PDU)
The 3-in-1 on-board charging system integrates an on-board charger (OBC), DC-DC converter, and a power distribution unit (PDU) into a single compact unit. This advanced system is designed for electric vehicles, offering a highly efficient and safe charging solution that simplifies the vehicle's architecture. By adopting an integrated design, the system ensures excellent heat dissipation, long service life, and high power density.
The DC-DC converter within the system converts high-voltage DC power from the main battery into low-voltage DC, providing energy for the vehicle's low-voltage loads and enabling the charging of the auxiliary battery. The 3-in-1 integrated charging system enhances efficiency by combining the charging, power conversion, and distribution functions into a single unit, making it ideal for modern electric vehicle architectures. This approach minimizes complexity and ensures the vehicle operates efficiently, while maintaining easy upkeep.
The PDU (power distribution unit) is responsible for distributing high-voltage electricity throughout the vehicle, much like a fuse box in a low-voltage electrical system. It consists of high-voltage relays and fuses, as well as integrated chips that enable signal communication with other modules, ensuring the safe use of high-voltage power within the vehicle.
The OBC (on-board charger) connects to the grid via an AC charging port or station, converting AC power into DC to charge the vehicle's high-voltage battery efficiently.
The DC-DC converter steps down high-voltage power from the main battery to low-voltage DC, providing power for the auxiliary battery and the vehicle's low-voltage systems.
| Nominal Voltage (V) | Nominal Current (A) | Cooling Method | Model of Lithium-ion Battery |
| 114V | 46A | Forced air cooling/Liquid cooling | CDU-LXX |
| 312V | 20A | Forced air cooling/Liquid cooling | CDU-LXX |
| 540V | 14A | Forced air cooling/Liquid cooling | CDU-LXX |
| Nominal Voltage (V) | Nominal Current (A) | Cooling Method | Model of Lithium-ion Battery |
| 114V | 23A | Forced air cooling/Liquid cooling | CDU-MXX |
| 216V | 17A | Forced air cooling/Liquid cooling | CDU-MXX |
| 312V | 10A | Forced air cooling/Liquid cooling | CDU-MXX |
The 3-in-1 on-board charging system (OBC + DC/DC + PDU) is widely used across a variety of new energy vehicles, including electric microcars, sedans, SUVs, commercial vehicles, buses, as well as electric yachts and forklifts. This integrated charging solution provides reliable, efficient power management for different types of new energy electric vehicles, ensuring versatility and compatibility.
The “3+3” compact structure of this EV charging system is designed to reduce the vehicle's wiring harnesses, connectors, pipelines, and enclosures, resulting in a more convenient layout.
This design and its wide range of applications aim to improve charging efficiency, safety, and reliability, marking a significant development in new energy vehicle technology.
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The first step in our custom solution process is a comprehensive analysis of the client’s company and background. Our solutions team conducts a deep dive to understand the scale of the client’s business and their target customer base. We compile relevant information and create a potential supplier evaluation report, allowing us to effectively analyze and meet the client’s specific needs.
During the analysis of client’s requirements, our design team carefully examines the specifications required for the custom on-board charger (OBC), DC/DC converter, or integrated charging system. This includes verifying parameters such as product type, power capacity, size, integration level, interface types, cooling methods, and intended use.
After all parameters have been verified and aligned with the needs analysis, our team proceeds with custom solution design. This phase focuses on improving or developing product molds and designing integrated PCB (Printed Circuit Board) layouts to meet the client's specific requirements in terms of integration and functionality.
