Combined transformer, resonance inductor unit targets on-board chargers
The Spanish power electronics manufacturer Premo has developed a triple 3.6 KW LLC set with transformer and resonance inductor specifically designed for on-board chargers capable of handling up to 11 kW of power. Its compact design, durability and high efficiency address the needs of OBC manufacturers.
The BCBM-11KW-004 series is a high-reliability and high-efficiency solution designed to minimize energy losses during the charging process, which helps to reduce the overall energy consumption of the charging system. This can be particularly important for electric vehicles, where efficient use of energy helps to maximize the vehicle’s range and minimize charging times.
The combined unit features a compact design, 158x98x38cm, and is lightweight, with only 1500g total weight, which makes it well-suited for use in electric vehicles on board chargers where space is at a premium. It is also designed to be highly durable and able to withstand the rigors of daily use in demanding environments.
The usage of 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.
Premo has developed a fully automatic manufacturing process for this kind of part design. The current production, in two different plants in Vietnam and Morocco, is fully automated by using cobots from Premo Robotics. Due to this high automatization level, the high volume demand coming from electric and hybrid vehicles is secured with top notch quality levels, the vendor advertises.
This solution offers a 14:15 Turn Ratio and main inductance value of 115uH. It provides a switching frequency of 98-150KHz andoutput voltage of 240-460V at a maximum of 14.7Arms. BCBM family includes solutions with 4kW, 7 kW, 11kW and 22kW. This set can be customized according to customer requirements.
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