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Today’s challenges with electrification

Electric cars

Mild hybrids

Light duty trucks, trucks and busses

High-end sports cars

Plug-in hybrid vehicles

EV motorcycles

Vehicle OEMs must meet lower CO₂ emission standards while increasing vehicle features and performance to remain competitive. This significant challenge is being met with vehicle electrification which is changing the power delivery networks within pure electric (EV), hybrid electric (HEV), and internal combustion vehicles (ICV). The addition of higher voltage batteries such as 48V, 400V and 800V to meet the increased power requirements has, in turn, increased the complexity of power delivery architectures and placed new demands on the size and weight of the vehicle’s power converters and regulators for battery charging, power conversion and power delivery.

Charging

Charging electric vehicles with either 400V or 800V batteries from any charging station

Conversion

Converting high voltage and high power batteries to new 48V systems and 12V legacy loads with high density, low weight converters

Delivery

New 48V based power delivery to legacy 12V loads and new drive, steer and brake by wire high power systems

Modular solutions

Vicor is enabling vehicle electrification with a high density, scalable, modular power solutions approach to power delivery. Our components replace the larger, heavier discrete solutions that are present in so many vehicles today, redefining power delivery networks and enabling vehicles to be lighter, faster and travel farther.

The benefits of Vicor modules

High density solutions

Modular and scalable architectures

Efficiency up to 98%

Lightweight

Vicor power delivery networks for charging, conversion and delivery

Charging

With 400V and 800V based charging stations being deployed, vehicle compatibility with any station requires simple and efficient conversion between the two voltages. The NBM6123 provides 6kW of 400V and 800V fixed-ratio conversion in a 63 x 23mm CM-ChiP package, enabling a high-efficiency and high-density scalable solution for battery-to-charger station compatibility. The bidirectional capability of the NBM6123 allows the same module to be used for either step-up or step-down conversion. In addition, the NBM6123 can also be used to provide a 400V source for air conditioning and cabin electronics during 800V charging, minimizing battery balancing circuitry.

NBM6123

Output current: 15A @400V, 7.5A @800V

Efficiency: 99.3% peak, 98.8% full load

61 x 23 x 7.4mm

Conversion

Converting a vehicle's primary high power HV battery with traditional solutions creates significant weight and space demands within the vehicle. In addition to the converter itself, a secondary, intermediate battery can also be required. The BCM6135 modules enable standard 800V and 400V batteries to be integrated into 48V power delivery networks reducing weight and space consumption. In addition, the BCM6135 provides bidirectional power conversion and fast transient response, eliminating intermediate energy storage at 48V. The BCM6135 can virtualize the HV battery to look like a 48V battery within the system.

400V BCM6135

Input: 260 – 410V

Output: 32.5 – 51.3V

Current: Up to 65A

61 x 35 x 7.4mm

900V BCM6135

Input: 520 – 920V

Output: 32.5 – 57.5V

Current: Up to 80A

61 x 35 x 7.4mm

1200V BCM6135

Input: 780 – 1,200V

Output: 32.5 – 50.0V

Current: Up to 80A

61 x 35 x 7.4mm

Delivery

New 48V based power delivery networks need to support legacy 12V loads with increased power requirements and new drive, steer and brake-by-wire high power systems. Providing increased power at 48V with a growing number of loads requires high-density modules versus larger and bulkier discrete solutions. Vicor offers several modules for power delivery from 48V. These devices include fixed ratio and regulated converter solutions that support both 48V and 12V loads. These converters can be contained in a single housing, or be deployed throughout the vehicle leveraging a smaller and lighter 48V power distribution network. DCM and PRM modules provide 48V to 12V and 48V to 48V regulated outputs, respectively. The NBM provides either 48V to 12V or 12V to 48V bidirectional, fixed ratio conversion.