3-in-1 (OBC DC/DC PDU)
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.
- 3-in-1 charging and distribution
- 3-in-1 powertrain electrification
- 3-in-1 Electric Axle
- 3-in-1 CDU Vehicle Charger
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.
- Input voltage: 114V-540V
- Cooling method: forced air cooling/liquid cooling
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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.
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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.
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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 |
- Input voltage range: AC90V-264V
- Frequency: 45Hz-65Hz
- Power factor: ≥0.99
- Full load efficiency: ≥93%
- Mechanical impact and vibration grade: QC/T 895-2011
- Protection level: IP67
- Operating temperature: -40℃ to 85℃
- Storage temperature: -40℃ to 105℃
- Communication: CAN bus
- Functions: output over-voltage/overcurrent/short circuit/reverse polarity protection, input undervoltage/over-voltage protection, over-temperature protection
- Nominal power: 1kW
- Peak power: 1.2kW lasting 6 minutes
- Output voltage/current: 14V±1% / 72A
- Max. efficiency: ≥95%
- Voltage regulation: 1%
- Voltage control accuracy: ≤1%
- Current control accuracy: ≤2%
- Operating temperature: -40℃ to 60℃
- Storage temperature: -40℃ to 105℃
- Communication: CAN bus/12V Enable Signal Control
- Functions: output over-voltage/undervoltage/short circuit protection, input reverse polarity protection, over-temperature protection, communication protection
- Dimensions (L×W×H): 260×244×95mm
- Cooling method: air cooling, water cooling
| 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 |
- Input voltage range: AC90V-264V
- Frequency: 45Hz-65Hz
- Power factor: ≥0.99
- Full load efficiency: ≥93%
- Mechanical impact and vibration grade: QC/T 895-2011
- Protection level: IP67
- Operating temperature: -40℃ to 85℃
- Storage temperature: -40℃ to 105℃
- Communication: CAN bus
- Functions: output over-voltage/overcurrent/short circuit/reverse polarity protection, input undervoltage/over-voltage protection, over-temperature protection
- Nominal power: 1kW
- Peak power: 1.2kW lasting 6 minutes
- Output voltage/current: 14V±1% / 72A
- Max. efficiency: ≥95%
- Voltage regulation: 1%
- Voltage control accuracy: ≤1%
- Current control accuracy: ≤2%
- Operating temperature: -40℃ to 60℃
- Storage temperature: -40℃ to 105℃
- Communication: CAN bus/12V Enable Signal Control
- Functions: output over-voltage/undervoltage/short circuit protection, input reverse polarity protection, over-temperature protection, communication protection
- Dimensions (L×W×H): 260×244×95mm
- Cooling method: air cooling, water cooling
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.
- Multi-functional integration This 3-in-1 system integrates the on-board charger (OBC), bidirectional inverter, DC/DC converter, and PDU, creating a unified power management and distribution system.
- High-efficiency charging It supports a wide voltage range from 240V DC to 490V DC while maintaining over 95% efficiency, ensuring fast and efficient charging for electric vehicles.
- High performance and reliability Utilizing the advanced topology and critical components, the on-board charging system undergoes rigorous global grid testing to ensure high performance and reliability.
- EMC compatibility The EV charging system provides high performance, power density, and reliability while ensuring excellent electromagnetic compatibility (EMC), contributing to stable and safe operation.
- Smart management and protection Through CAN communication with the Battery Management System (BMS), the 3-in-1 on-board charging system enables intelligent charging management and fault monitoring, offering multiple protection mechanisms, such as over-voltage and short-circuit protection.
- Flexible voltage output This integrated power system offers multiple voltage output options to meet the needs of different vehicle models and battery systems, with a liquid-cooling design that enhances heat dissipation and operational stability.
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.
