Wanda Group launches 22KW OBC combined with 3KW DC/DC car charger solution based on ST products

On April 20, 2023, WPG Holdings, a leading semiconductor component distributor dedicated to the Asia-Pacific market, announced that its subsidiary U-Shang Group has launched a 22KW OBC combined with a 3KW DC/DC direct current output car charger solution based on the STELLAR-E1 series SR5E1 chip, jointly developed with STMicroelectronics (ST).

Figure 1- Display board of 22KW OBC combined with 3KW DC/DC car charger solution based on ST products of Dalian Dayoushang

With the gradual improvement of energy-saving and environmental protection awareness and the continuous advancement of carbon neutrality goals, the global automotive industry is accelerating into the era of electrification. However, although the shipment volume of electric vehicles has increased year by year in recent years, its endurance and charging costs have always been controversial. In order to solve these problems, the new generation of electric vehicle solutions not only need to achieve longer endurance and faster charging speed, but also reduce the weight of the vehicle as much as possible to meet the basic travel needs of consumers. In this case, in order to meet the charging requirements of high-voltage batteries, the third-generation semiconductor silicon carbide (SiC) and gallium nitride (GaN) power devices are used in automotive systems to improve the energy efficiency and reliability requirements of on-board chargers (OBCs) and various DC/DC converters . However, in the design of on-board power systems, due to the requirements of high-precision control operations and vehicle safety, ordinary automotive-grade MCUs can no longer meet higher computing power and higher levels of safety functions, nor can they support the higher switching frequency of gallium nitride (GaN) power transistors. The traditional solution design requires a DSP chip and an additional automotive safety chip to specifically handle the control loop and safety performance requirements, which undoubtedly increases the complexity and difficulty of the system. To simplify this challenge, Dalian Dayoushang launched a 22KW OBC combined with a 3KW DC/DC car charger solution based on the ST STELLAR-E1's SR5E1 chip. This solution helps reduce the cost of electric vehicles while speeding up charging, improving vehicle safety, and extending driving range.

Figure 2-Application scenario of 22KW OBC combined with 3KW DC/DC car charger solution based on ST products of Dalian Dayoushang

SR5E1 is a high-performance product in ST's STELLAR-E1 series of electric vehicle MCUs. It is a dual-core MCU that meets the automotive standard ISO26262 ASIL-D level and has a computing power of 300MHz. It realizes the execution of high-speed control loop processing and general control operations on the same chip. By utilizing the features of the on-chip integrated high-speed analog-to-digital converter (ADC), high-precision pulse width modulation (PWM) controller and fast-action protection circuit, only one MCU is needed to control the entire power module and meet the automotive safety requirements. This greatly simplifies the design of the on-board charging system and streamlines the bill of materials, which is conducive to promoting the transition of the on-board charging system to an efficient solution based on the third-generation semiconductor, greatly meeting the charging specifications of the high-voltage battery, thereby achieving longer driving mileage and faster charging speed.

At the same time, the STELLAR-E series MCU also gives electric vehicles the ability to upgrade software. It supports advanced automotive functional safety standards (ISO 26262 ASIL-D) and data security functions (HSM), meets industry standard software interoperability (AUTOSAR 4.3.x), and has built-in efficient and secure over-the-air (OTA) reprogramming, which can continuously optimize performance and upgrade vehicle functions.

Figure 3- Block diagram of 22KW OBC combined with 3KW DC/DC car charger solution based on ST products of Dalian Dayoushang

Through the outstanding capabilities of the STELLAR-E1 MCU, this solution can ensure fast, high-precision instant control of power conversion, maximize the technical advantages of SiC and GaN third-generation semiconductor power devices, meet the high efficiency and reliability of electric vehicle charging, and enable automakers to improve and optimize system design to further improve the vehicle's mileage, performance and energy efficiency.

Core technology advantages:

 Requirements for electric vehicles include powerful hardware devices to ensure efficient power conversion and performance with excellent safety and reliability.

The ability to receive regular over-the-air software updates is central to the functionality enhancements and ensures critical security and updates throughout the vehicle lifecycle.

Improved user experience through enhanced range and performance as well as the latest safety updates.

Through superior automotive components, we combine advanced digitalization with efficiency and innovation to support the sustainable development of electric vehicles.

Program Specifications:

 CRM controls single-phase/three-phase bridgeless totem-pole PFC:

Input : 304Vac-456Vac;

Output : 450Vdc-900Vdc;

 22KW OBC:

Input : 450Vdc-900Vdc;

Output : 36A Idc Max;

 3KW DC/DC:

Input : 800Vdc /3.75A Idc;

Output : 14Vdc / 215A Idc.