High Power DC EV Charger 30kW-240kW Fast Charging Station
- Power Output: 30kW to 240kW Modular
- Voltage Range: 200V - 1000V DC
- Protection Level: IP54 Outdoor Heavy-Duty
Engineering Whitepaper: Onboard Charging (OBC) & High-Voltage Power Electronics
As global transport electrification accelerates toward 800V powertrain architectures, procurement teams and vehicle engineers require onboard charging equipment and DC conversion modules capable of withstanding extreme electrical, thermal, and mechanical stress. Onboard Chargers (OBC) serve as the primary link between the alternating current (AC) grid and the high-voltage traction battery pack. Modern B2B automotive procurement demands not merely off-the-shelf conversion devices, but deeply integrated power systems incorporating wide-bandgap (WBG) semiconductors, bidirectional grid connectivity (V2G), and full CANbus/J1939 telematics capabilities.
Our engineering architecture combines decades of German power-electronics mastery with modern automated mass production. By uniting planar transformer topologies with liquid and contact cooling solutions, our onboard conversion systems deliver industry-leading power density exceeding 3.8 kW/L while maintaining strict compliance with automotive functional safety standards (ISO 26262 ASIL-B/D) and industrial EMI limits (CISPR 25 Class 5).
SiC Power Topologies
Silicon Carbide (SiC) MOSFET switches enable switching frequencies above 150 kHz, dramatically shrinking passive inductor volumes and elevating thermal conversion efficiency up to 97.5%.
Galvanic Isolation & Safety
Reinforced insulation barriers rating over 3.75 kVAC prevent high-voltage traction bus noise from polluting sensitive low-voltage 12V/24V ECU control circuitry.
Ruggedized Potting Enclosures
Fully potted polyurethane and silicone encapsulations guarantee IP67/IP69K ingress protection, rendering electronics immune to continuous vibration, chemical spray, and dust.
Production Line & OEM Assembly Charging Computers
In vehicle manufacturing facilities, battery chargers are subjected to uninterrupted 24/7 duty cycles. Our specialized charging computers safeguard lithium-ion and lead-based battery chemistry across every phase of manufacture: from initial module flashing, through end-of-line (EOL) vehicle testing, to showroom preservation.
Featuring proprietary DC-Connect network integration, manufacturing leads can track real-time charging curves, voltage drop profiles, and serial-number-linked quality data across the entire plant layout.
High-Voltage DC/DC Converters (DVCx3 & DVCHx3 Series)
Converting high battery pack voltages down to stable 12V, 24V, or 48V auxiliary rails requires exceptional switching stability. The DVCx3 series manages conventional lower DC input ranges, while the DVCHx3 series seamlessly operates on input platforms reaching up to 900V DC.
Utilizing cold-plate contact cooling, these systems bypass the weight and mechanical complexity of dedicated liquid lines, making them the preferred power transformation module for mining rigs, e-buses, and rail locomotives (EN 50155 compliant).
D-Sinus Sinusoidal Commutated Motor Controllers
Square-wave motor drive signals introduce significant acoustic noise, torque ripple, and thermal losses. The D-Sinus controller family regulates motor excitation currents to a pure sine wave format. This approach minimizes electromagnetic interference (EMI) while delivering smooth low-speed torque control for electric power steering pumps, hydraulic actuators, and cooling fans in noise-sensitive cabin environments.
