Overcoming Design Hurdles: Developing a 95.5% Efficient, 3.8L Compact 11kW On-Board Charger

When designing an 11kW on board charger (OBC), several factors must be taken into account to optimize performance and ensure the product meets the demands of modern electric vehicle (EV) charging. At AcePower, we understand the challenges and have focused on creating a solution that balances size, efficiency, and versatility. The OBC 11kW offers high efficiency and compact design, but developing such a system requires overcoming specific engineering hurdles. Here’s a look at the key design challenges faced during development.

Maximizing Efficiency While Minimizing Size

One of the foremost challenges in the development of the 11kW on-board charger was achieving high efficiency while maintaining a compact footprint. With a compact size of just 3.8L, the charger integrates both a bidirectional OBC and multifunctional DCDC converter. At AcePower, we worked hard to ensure the charger’s efficiency reached up to 95.5% at full load operation. This was no easy task, but optimizing the internal components allowed us to significantly reduce energy waste during conversion. The reduced physical size, which roughly equals stacking a few standard water bottles, makes installation easier, saving space within the vehicle. Moreover, the smaller form factor enhances the flexibility of installation, allowing the 11kW on-board charger to be seamlessly integrated into a wide variety of vehicle models, from compact cars to larger EVs, without compromising on performance or taking up valuable cargo space.

Handling Complex Charging Scenarios

The 11kW OBC is designed to cater to diverse EV charging scenarios, which require handling both single-phase and three-phase currents. Managing the current flow through the onboard charger efficiently is crucial to avoid overheating or damaging sensitive components. With the ability to support up to 32A AC for single-phase and 16A AC for three-phase, AcePower engineers ensured the system adapts seamlessly to various vehicle models and user charging needs. The 11kW on-board charger supports intelligent CAN communication, enabling integration with advanced smart energy management systems, a crucial step in meeting the future demands of EV infrastructure.

Ensuring Long-Term Stability and Reliability

An essential aspect of any EV charging system is its reliability over time. The 11kW on-board charger from AcePower must perform under a range of temperature variations and charging cycles. In designing the system, we considered how to maintain stable and reliable performance even in challenging environments. The charger’s robust internal architecture ensures minimal performance degradation, even after extensive use. With its excellent thermal management and efficiency, users can trust that the OBC 11kW will operate consistently, providing an uninterrupted charging experience over the years. Additionally, the charger’s built-in protection mechanisms, such as over-voltage, over-current, and short-circuit safeguards, further enhance its reliability, ensuring that it continues to deliver safe and efficient charging under a wide range of operating conditions, providing peace of mind for both users and vehicle manufacturers alike.

Engineering Breakthrough: A Compact, High-Efficiency 11kW OBC

Developing an 11kW on-board charger involves overcoming challenges related to efficiency, adaptability, and long-term reliability. At AcePower, we strive to offer a product that balances all these factors, resulting in a reliable, efficient, and compact charger. By addressing these challenges head-on, we are proud to present a solution that meets the growing demands of modern electric vehicles. Furthermore, our continuous commitment to innovation and quality ensures that the 11kW on-board charger not only meets current industry standards but is also future-proof, ready to support advancements in EV technology and the evolving needs of the electric mobility sector.