11 KW on-board charger combines transformer and resonance inductor
Premo in Spain has developed an efficient triple 3.6 KW on-board charger with transformer and resonance inductor that can handle up to 11 kilowatts of power.
The compact design, durability and high efficiency of the BCBM-11KW-004 is intended to minimize energy losses during the charging process, helping reduce the overall energy consumption of the charging system. This can be particularly important for electric vehicles, where efficient use of energy can help to maximize the vehicle’s range and minimize charging times.
The combined unit measures 158 x 98 x 38cm and weighs 1500g, making it suitable for use in electric vehicles on board chargers. Using a specific thermal conductive encapsulation material, like Coolmag, improves the performance capability of the part. During manufacturing, the encapsulation process is made guaranteeing no bubbles or voids inside the part, removing the chances of thermal runaways or failures.
The design has a 14:15 Turn Ratio and main inductance value of 115uH. It provides a switching frequency of 98-150KHz and output voltage of 240-460V/<14.7Arms. THe BCBM family includes solutions with 4kW, 7 kW, 11kW and 22kW and can be customized according to customer requirements.
Premo has developed a fully automatic manufacturing process for this kind of part design. The current production, deployed in Vietnam and Morocco is fully automated by using cobots from Premo Robotics.
The design will be presented at PCIM Europe 2023 in May.