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Maximizing vehicle weight reduction with high-density power DC-DC modules

Presented by Greg Green, Director of Automotive Marketing, Vicor

EV’s have an issue with being heavier than ICE vehicles which drives issues with range, tire wear and infrastructure. There are large weight reductions that can be gained by using high power density DC-DC modules to improve the weight and performance of the vehicle power distribution network. These modules can support the downsizing of the DC-DC charger and OBC to sizes that reduce weight by 50%, additionally by reducing the size of these systems by over 50% they can be integrated into the traction battery housing. The implementation of the 48V Zonal Architecture can be optimized with the high power density D-DC modules; by supporting the creation of local 12V busses from the main 48V bus to achieve wire harness weight reduction of up to 85%. Lastly the use of the high power density DC-DC module can facilitate the removal or major downsizing of the low voltage batteries in an xEV to create substantial weight reduction. The sum of these improvements will generate up to 20kg of weight reduction in a vehicle.

Greg Green has over 33 years of experience in the automotive industry, spanning across manufacturing, design engineering and product line management with OEM’s, and Tier 1 suppliers. Greg’s auto industry experience includes manufacturing, product development, and business development. Greg holds a B.S. Degree in Aerospace Engineering from the University of Michigan, and an M.S. in Manufacturing Management from Kettering University.

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Designing 48V zonal architecture that keeps the high-voltage inside the BEV battery pack

Presented by YK Choi, Sr. Field Application Engineer, Vicor, APAC

The future BEV systems will be required lots of heavy loads and safety system with 12V legacy power. The OEMs will put several DC-DC converters in vehicle to support this power demand, however this activity is not good solution to support this power demand. Someone try to change the power distribution concept from domain to Zonal control. The key factor of Zonal architecture is power distribution, expand I/O port and data gathering from point of loads.

YK Choi is Senior Field Application Engineer at Vicor, APAC. YK has over 26 years of experience in power electronics, power modules (IGBT, SiC), discrete switches and semiconductors. He has expertise in vehicle electrification based on traction inverter systems. Mr. Choi has held positions as an R&D engineer and as a field applications engineer in semiconductor test equipment and has also worked at Infineon Technologies. He has MS in Power Electronics and BS in Electrical Engineering from Konkuk University in Korea.