We provide a proven 6.6 kW bidirectional OBC + 2.5 kW DC/DC converter that integrates high-voltage battery charging, V2L inverter operation, and low-voltage power supply in a single liquid-cooled unit. The product is already in production and has been deployed in volume applications, providing a proven solution for EV platforms requiring integrated high- and low-voltage power conversion.
The two-in-one unit combines a 6.6 kW OBC, 2.5 kW DC/DC converter, and 3.3 kVA V2L output in a compact package, with CAN communication, IP67 protection, and liquid cooling.
Key Features
- 6.6 kW OBC with 90–264 Vac input
- Bidirectional power conversion with up to 3.3 kVA VTL output
- 2.5 kW DC/DC converter with 3 kW peak output for 6 minutes
- Liquid-cooled integrated design
- >95% OBC efficiency and ≥94% efficiency in VTL and DC/DC modes
- CAN communication for interaction with the BMS and VCU
- IP67 protection
- Operating temperature from −40°C to +85°C
- Compact dimensions of 272 × 200 × 68 mm excluding faucets and connectors
1. Integrated OBC + DC/DC Architecture
The product integrates two power conversion functions in one unit.
During AC charging, the OBC converts 90–264 Vac from the grid into DC power for the vehicle’s high-voltage battery. The vehicle controller can monitor and control the charging process through CAN communication.
The integrated DC/DC converter converts 200–450 Vdc from the high-voltage battery into regulated low-voltage power, providing a 14.5 V output for the vehicle’s low-voltage electrical system and battery charging.
The OBC and DC/DC converter exchange voltage, current, and operating-status information through CAN, supporting communication with the vehicle’s BMS and VCU.
2. 6.6 kW Bidirectional OBC with V2L Function
In addition to conventional AC charging, the OBC supports V2L (Vehicle-to-Load) inverter operation. In this mode, power flows from the high-voltage battery to an AC load: HV Battery → OBC → 220 Vac Output
The V2L function provides up to 3.3 kVA of AC output power.
| Parameter | VTL Mode |
|---|---|
| HV input voltage | 250–450 Vdc |
| Rated input voltage | 360 Vdc |
| Maximum input current | 15 A |
| AC output voltage | 220 Vac ±15% |
| Output frequency | 50 ±1 Hz |
| Maximum output current | 16 A |
| Maximum output power | 3.3 kVA |
| Efficiency | ≥94% |
| Output voltage THD | <3%* |
* For purely resistive loads or rectifying loads with a peak ratio ≤3.
3. 6.6 kW OBC Charging Performance
The OBC supports a wide AC input range of 90–264 Vac and provides up to 6.6 kW of charging power.
| Parameter | Specification |
|---|---|
| AC input voltage | 90–264 Vac |
| Rated input voltage | 220 Vac |
| Input frequency | 45–65 Hz |
| Maximum input current | 32 A |
| Power factor | ≥0.99 |
| Input current THD | <5% |
| Efficiency | >95% |
| HV output voltage | 210–450 Vdc |
| Rated output voltage | 360 Vdc |
| Rated output current | 18.3 A |
| Maximum output current | 20 A |
| Rated output power | 6.6 kW |
| Output voltage accuracy | ≤±1% |
| Output current accuracy | ≤3% @ >10 A; ≤0.3 A @ <10 A |
| Output power accuracy | ≤±2% |
| Output voltage ripple | ≤±2% |
The OBC incorporates the required CC and CP detection and control functions and supports communication with the BMS for charging control.
4. 2.5 kW DC/DC Converter
The integrated DC/DC converter converts the high-voltage battery output into regulated low-voltage power for the vehicle.
| Parameter | Specification |
|---|---|
| HV input voltage | 200–450 Vdc |
| Rated input voltage | 360 Vdc |
| Maximum input current | 12 A |
| LV output voltage | 14.5 V ±0.25 V |
| Output current | 173 A |
| Continuous output power | 2.5 kW |
| Peak output power | 3 kW @ 6 min |
| Efficiency | ≥94% |
| Output voltage accuracy | ≤±1% |
| Output voltage ripple | ≤500 mVp-p |
| Output voltage overshoot | ≤5% |
The DC/DC converter supports a 9–16 Vdc low-voltage input range and a quiescent current of ≤0.8 mA.
5. CAN Communication and Vehicle Integration
The OBC and DC/DC converter use CAN communication for control, status feedback, and information exchange with the vehicle’s BMS and VCU.
The system supports:
- CAN communication at 500 kbps
- Customer-defined communication protocols
- CAN-based voltage and current control
- BMS and VCU information exchange
- High-voltage interlock monitoring
- UDS diagnostic functions
- Multiple wake-up methods
The OBC supports CC resistor, CP, hard-wire, and CAN wake-up, while the DC/DC converter supports hard-wire wake-up.
Software parameters and communication functions can be configured according to vehicle application requirements.
6. Liquid Cooling and Protection
The integrated unit uses liquid cooling to manage the thermal load of the OBC and DC/DC power stages.
| Parameter | Specification |
|---|---|
| Cooling method | Liquid cooling |
| Coolant | 50% water + 50% ethylene glycol |
| Minimum coolant flow | ≥6 L/min |
| Normal coolant temperature | −40°C to 65°C |
| Derating range | 65°C to 85°C |
| Operating temperature | −40°C to +85°C |
| Storage temperature | −40°C to +95°C |
| Relative humidity | 5–95%, non-condensing |
| Altitude | Up to 5 km |
| Protection rating | IP67 |
The system includes protection functions for key electrical and thermal conditions, including:
- Input overvoltage and undervoltage
- Output overvoltage and undervoltage
- Overcurrent
- Short circuit
- Overtemperature
When coolant temperature rises above the specified range, the system applies power derating before entering overtemperature protection.
7. Compact Integrated Package
The OBC and DC/DC converter are housed in a compact water-cooled enclosure.
| Parameter | Specification |
|---|---|
| Dimensions (L × W × H) | 272 × 200 × 68 mm* |
| Weight | ≤6.5 kg |
| Cooling | Liquid cooling |
| Protection rating | IP67 |
* Excluding faucets and connectors.
The integrated design combines the two power conversion functions into one package, helping simplify installation and reduce the number of separate power electronics units required at vehicle level.
Conclusion
This 6.6 kW bidirectional OBC + 2.5 kW DC/DC converter combines AC charging, V2L inverter operation, and low-voltage power conversion in one production-proven unit. It’s designed for EV platforms requiring compact and integrated power electronics.
The product is already in production and used in volume applications, providing a mature platform for vehicle manufacturers and system developers evaluating integrated OBC + DC/DC and bidirectional OBC solutions.
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