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The global electric vehicle Onboard Charger (OBC) market is estimated to reach $10.82 billion by 2027, registering a CAGR of 22.4% from 2020 to 2027. With OBCs that on average give 25% higher DC-DC rating and ~30% reduction in charge duration, Electra EV has been developing OBCs which have helped electric mobility applications exceed end-user expectations.
Onboard charger(OBC) is a device that convert ac power from any ac source into the practical dc form. It is usually mounted inside the vehicle and it’s main function is power conversion. Hence, on board chargers provides the advantage of charging the electric vehicle using the power outlet at our homes itself. In addition, it also eliminates the need for buying any extra equipment for power conversion.
The specifications of the battery charger influence the charging time and battery life. Let us look into detail about an OBC.
Another function of OBC is that it controls the level of current and voltage at which the battery is charged. There are mainly two types of charging : constant voltage and constant current charging. Even though constant current charging provides high efficiency and high charging speed it can affect the lifespan of the battery. This is due to over-charging. In the case of constant voltage charging, there is a chance that a high amount of current can flow into the battery initially.
The above problem can be solved by charging the battery initially by constant current charging. Then after reaching a certain amplitude, the battery is charged using constant voltage charging. This charging strategy is the most important role of an EV on board charger.
Difference between AC and DC chargers
In AC charging level 1 and level 2, the AC power from the grid is converted to DC power by the OBC to charge the battery via the Battery Management System(BMS). The voltage and current regulation is performed by the OBC. In addition, the disadvantage of AC charging is as its charging time increases, the power output becomes low.
The charging rate, or required input current, is determined by the EV itself in AC chargers. Because not all electric vehicles (EVs) require the same amount of input charging current, the AC Charger must communicate with the EV to determine the required input current and establish a handshake before charging can commence. This communication is referred to as Pilot wire communication. The Pilot wire identifies the type of charger attached to the EV and sets the OBC’s required input current.
In DC fast charging or Level 3 charging, the AC power from the grid is directly supplied to the Battery Pack. As shown in the figure above, we can see that there is a AC/DC converter in-built in the DC charger itself. Hence it eliminates the need for OBC in this level of charging. Therefore, this helps in reducing the charging time. The EVSE is arranged in stacks to deliver high current because a single stack will not be able to supply high current. Hence, there is no role of OBC in DC Charging.
This classification is based on the number of phases it can use. The output of a standard single phase OBC is 7.2-7.4 kWh. While, that of a three-phase OBC is 22kWh. As a matter of fact, the OBC is able to detect which type of input it can accept. When connected to only one phase, the power that this on board charger can tolerate is 110 – 260 V AC (and 360 – 440V in the case of using three phases). The battery receives a voltage between 450 and 850 volts as an output.
In OBCs using a rectifier, high power AC input is converted to DC power and provides Power Factor Correction. To boost the power factor to unity, a power factor correction (PFC) circuit removes harmonic distortion in the supply current and provides a current waveform that is close to a basic sine wave. This section of the charger determines whether it can use one, two, or all three alternating current phases. In addition, the DC/DC converter must isolate the power grid from the HV dc bus and the HV dc bus from the LV dc bus for safety reasons.
The second phase receives the 700V output voltage. The resultant DC signal is chopped into a square wave, that drives a transformer. This further provides the required DC voltage. An isolated CAN bus can be used to monitor and control the entire system. Digital isolators and digital isolators with integrated DC/DC power converters are used to isolate the CAN. Finally, the required voltage is supplied to the battery.
During the period 2020-2025, the worldwide automotive EV onboard charger market is expected to grow at a CAGR of around 30% the projected term, growing sales of electric vehicles, strict pollution laws, developments in battery technology, and improved charging infrastructure are expected to boost demand for automotive onboard chargers. Electric passenger vehicles are already being adopted in developed nations, and new startups and significant players in the EV sector are aiming to launch their own new electric models in the next years.
Studies and developments are focusing on developing more efficient and light weight onboard chargers. Because development can help in the advancement of electric vehicle industry. Many established and emerging countries have framed their green mobility plans, which include prohibiting diesel vehicles and providing incentives to buyers of electric vehicles. By 2030, India intends to prohibit all diesel-powered vehicles off the roadways.
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An onboard charger (OBC) is a crucial component in electric vehicles (EVs), tasked with converting AC power from the grid to the DC power that charges the vehicle’s battery pack. Understanding what is an onboard charger and its function in an electric vehicle can provide insights into how EVs harness external power sources effectively.
Exploring the differences between on board and off board chargers, the specifics of a 11kw triphase onboard charger, and the global trends in high-power onboard chargers for electric vehicles sheds light on the technological advancements in the field. This article aims to demystify the onboard charging process, detailing how onboard battery chargers work and their role within the broader EV charging ecosystem.
At the heart of electric vehicle (EV) technology, the onboard charger (OBC) plays a pivotal role in managing the charging process, ensuring that the vehicle’s battery is charged efficiently and safely. Here’s a closer look at how onboard chargers function and their significance in the EV ecosystem:
The OBC converts alternating current (AC) from the grid into direct current (DC), which is suitable for charging the vehicle’s battery. This process involves two key stages:
A unique feature of some OBCs is their ability to support bidirectional charging, meaning they can also convert DC power from the vehicle’s battery back to AC power. This functionality enables:
Understanding these aspects of onboard chargers illuminates their critical role in the broader context of EV technology and infrastructure, highlighting their contribution to the efficiency, safety, and versatility of electric vehicles.
This article might interest you: Exploring the Innovation in Automotive Battery Thermal Management Systems
Electric vehicles (EVs) are equipped with onboard chargers (OBCs) that vary in their charging capabilities and characteristics, catering to the diverse needs of EV owners. Here’s a closer look at the types of onboard chargers and their distinct features:
As electric vehicles (EVs) continue to evolve, the technology behind onboard chargers (OBCs) faces both challenges and significant advancements. The shift towards higher voltage charging infrastructure, particularly 800V batteries, marks a pivotal step in enhancing EV performance and reducing charging times. This is further complemented by the development of traction-integrated onboard chargers (iOBCs) that leverage the high-powered electronics of the EV for faster charging while stationary. The adoption of 800V platforms and traction iOBCs in numerous commercial and passenger EV models underscores the industry’s commitment to improving charging efficiency.
However, the transition to advanced charging technologies like the 11kW triphase onboard charger introduces complexities, particularly for home installations. These chargers necessitate a three-phase electricity supply, which is not standard in single-phase properties, thereby limiting their applicability. The cost associated with installing an 11kW charger, ranging between £1,200- £1,800 excluding infrastructure upgrades, presents another barrier. Moreover, the lack of standardized EV charging protocols and the need for uniform fast DC charging standards highlight the ongoing challenges within the industry.
Advancements such as the development of two-way onboard chargers (V2G) for electric and plug-in hybrid vehicles promise to revolutionize the market by enabling energy flow back to the grid. This, coupled with strategic enhancements from key industry players and the global proliferation of charging infrastructure, points to a future where EV charging is more accessible and efficient. Yet, utility upgrades, electricity rates, and the need for extensive infrastructure investment for curb-side charging remain significant hurdles to widespread EV adoption.
The future of onboard charging and EV technologies is poised for significant advancement, driven by a blend of innovation, regulatory support, and market dynamics. Key developments include:
These advancements, coupled with increased public and private investment in charging infrastructure, are setting the stage for a transformative era in electric vehicle technology. The integration of renewable energy sources and the development of intelligent charging solutions are expected to further enhance the efficiency and sustainability of EV charging, making electric vehicles an increasingly viable and attractive option for consumers worldwide.
Understanding the distinction between onboard and offboard chargers is crucial for electric vehicle (EV) users to make informed decisions about their charging options. Here’s a concise comparison based on key aspects:
About Onboard charger electric vehicle
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