All-in-one PCU Handles Inverter-charger Functions of Off-road and Industrial EVs

The Bel-Fuse e-Mobility product group offers a range of onboard power conversion products for hybrid and electric vehicles.

 

Off-road, marine, and industrial e-mobility applications. Image used courtesy of Bel-Fuse

 

In the e-Mobility product group, Bel announced the latest model in its BCV200 all-in-one power converter units (PCUs) series. Designed to accommodate newer, higher voltage batteries in heavy-duty electric vehicles (EVs), the BCV200-700-8 is an integrated power conversion unit capable of delivering 15 kW of bi-directional charger-inverter power, 4 kW of step-down DC power at 12 V and 1 kW of step-down DC power at 24 V. 

Typical applications for the new power unit include hybrid and electric vehicles and medium through heavy duty, on- and off-highway electric vehicles.

 

Image used courtesy of Bel-Fuse

 

All-in-one Power Conversion Unit

The bi-directional charger/inverter portion of the module accommodates 50/60 Hz AC input/output power up to 240 V and DC battery voltages up to 850 V.  

In charge mode, the unit converts external, split-phase input AC power to high-voltage DC for charging the vehicle’s powertrain battery pack. When used as an inverter, high voltage DC from the batteries is converted to split phase AC power and delivered off-module through an external connector (AC side export connector).  

Output AC power can be used to power external or auxiliary loads directly from the battery or to transfer power back to the grid. 

AC charging power is provided to the unit through the external AC side charge connector, while the vehicle’s high-voltage battery pack is connected to the unit through the external HV power connector.

Output voltage and current levels for the 12 V and 24 V DC down converters are both CAN adjustable, with the 12 V converter delivering up to 278 A of load current and the 24 V converter providing up to 34.7 A.

The inverter-charger unit has a typical power conversion efficiency of 92% to help support fast charging and reduce thermal losses.

 

BCV200-700-8 power conversion unit. Image used courtesy of Bel-Fuse

 

Three Systems in One Reduces Cabling

Many medium- to heavy-duty and other EVs require multiple DC bus voltages for operation. Combining three conversion systems into a single module, the BCV200-700-8 reduces an EV’s cabling requirements, associated costs, and complexity by combining three conversion systems into a single module.  

 

BCV200-700-8 functional schematic. Image used courtesy of Bel-Fuse

 

Thermal Management and Protection

The BCV200-700-8 is designed for efficiency to minimize wasted energy in the form of heat. Even so, the high power rating necessitates liquid cooling of the unit. The cooling system uses 50/50 ethylene glycol/distilled water and is specified for a coolant flow rate of 7-10 LPM and system pressure up to 26 psig (1.8 bar). The 1/2” barbed hose fittings are provided to direct coolant to and from the system.

The module features a range of internal protective functions, including over temperature, output overvoltage, and overcurrent protection.

The BCV200-700-8 complies with IP67 and IP6K9K standards for water and dust and meets SAE J1455 environmental standards.

The unit ships in a 25.59 x 3.94 x 19.33 (inches) aluminum alloy enclosure and weighs 35.7 kg.

 

EV Power Conversion Solutions

Along with the BCV200-700-8, Bel-Fuse offers a broad range of power conversion products targeted toward light- to heavy-duty EV applications, including DC-AC inverters, DC-DC converters, and AC-DC chargers.

 

 

Light duty truck EV power conversion solutions. Image used courtesy of Bel-Fuse