At Onplick, we are committed to developing advanced power electronics solutions that push the boundaries of efficiency and reliability. One of our key innovations is a high-voltage, high-power AC/DC power supply unit designed for bi-directional EV chargers. This cutting-edge system delivers up to 20kW of bidirectional power, enabling both charging from the grid to the vehicle and energy return from the vehicle to the grid (V2G).
The project was driven by the need for a compact, efficient, and highly integrated power conversion solution. Our design incorporates a Vienna PFC topology in the AC/DC conversion stage, ensuring high power factor correction while minimizing harmonic distortion. This approach enhances efficiency and grid compatibility, making the power supply ideal for modern EV charging infrastructures. For the DC/DC stage, we implemented a resonant LLC topology, which significantly improves efficiency and reduces electromagnetic interference (EMI).
A crucial aspect of this project was the design of custom high-frequency transformers, tailored specifically for the DC/DC conversion stage. These transformers optimize power transfer while maintaining a compact footprint. The entire power supply unit is engineered as a single PCB solution, which simplifies manufacturing, improves thermal management, and enhances reliability.
Firmware development
To ensure smooth operation and integration with EV systems, we developed custom firmware that manages power conversion across both stages. The firmware also facilitates communication via the CAN protocol, enabling real-time monitoring and control. This level of intelligence allows the power supply to respond dynamically to charging demands while ensuring system stability and performance.
Compliance
Meeting regulatory compliance was a fundamental part of the project. The power supply successfully passed CE certification requirements, including EMC compliance (EN 61000-6-3 and EN 61000-6-2), safety standards (EN 62368-1), and grid compliance regulations (EN 61000-3-2 and EN 61000-3-3). Achieving these certifications validates the unit’s readiness for global deployment and market adoption.
The final product stands out for its high efficiency, exceeding 97%, while maintaining a compact form factor. Its robust thermal management and seamless CAN communication ensure long-term reliability and easy integration into charging infrastructures. By developing this innovative power supply, Onplick continues to drive the future of sustainable transportation, delivering efficient and intelligent power solutions for the evolving EV market.
