OBC Product Training V04.0

OBC Product
Training
OBC/DCDC Platform
Rev Date
V01.1 06.02.2018
V02.1 24.05.2018
valeo-siemens.com V03.4 06.11.2020
V04.0 07.04.2022
Restricted © Valeo Siemens eAutomotive 2022 07.04.2022 PL - PE R&D RFQ & ST OBC / J. Schulz Page 1
Training informations
Expected duration: ~ 4h
Training objectives
● Get knowledge on On Board Charger product line history, portfolio, functionalities,
market trends and roadmaps
● Understand key technologies in OBC design: OBC architectures, AC/DC and DC/DC
topologies, key components, product integration, cost…
● Be able to be integrated into OBC projects quickly after this training
Expected audience:
● VSeA newcomers
● Newcomers on OBC Projects
● VSeA employees who want to get knowledge on OBC
Trainee Introduction
Overview
1 Introduction
1.1 Introduction to VSeA
1.2 Introduction to OBC products
1.3 OBC Market Trends and Competition
1.4 OBC History, Roadmap & Portfolio
2 OBC Technical Specification & Architecture Overview
3 Power Conversion
3.1 Power Factor Correction
3.2 Resonant Converter and LLC
3.3 Bidirectional Function
3.4 Hardware Design
4 Product Integration & Validation
4.1 Product Mechanical Integration
4.2 OBC Thermal Design
4.3 Manufacturing Process
4.4 Prototype / Product Validation
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
Introduction to VSeA
Combined power of two successful companies
Valeo contributes Business mandate Siemens contributes

▪ Automotive business ▪ Worldwide business ▪ Strong global brand,
expertise presence especially in China
▪ Certified production lines for ▪ Coverage of the segments ▪ Excellent design
electronics passenger cars and light competence in electric
▪ Worldwide automotive commercial vehicles motors
customer base for ▪ Broad portfolio in ▪ Strong experience in
powertrain systems high-voltage products inverters
▪ A 50% – 50% joint venture between Siemens and Valeo for powertrain components for electrified passenger
cars and light vehicles
VSeA Scope
Siemens AG Valeo S.A.
The business: The business:
▪ to design, develop and produce ▪ high voltage applications over 60V
▪ electric motors: synchronous and asynchronous motors as main ▪ high power electronics systems
drive, hybrid drive or integrated / embedded solutions (Inverters, DC-DC Converters)
▪ power electronics: inverters, DC-DC-conversion and combined ▪ energy conversion products (on board chargers)
power electronic products
▪ e-motors (including 300V Range extender)
▪ charging solutions, mechanical and other components: onboard
chargers, inductive charging, mechanical and other components for
drive train solutions
▪ with a voltage level exceeding 60V
▪ for use and installation in passenger cars and light or medium

commercial vehicles
The product portfolio of Valeo Siemens eAutomotive
The product portfolio of Valeo Siemens eAutomotive
Motor Integrated Motor System Inverter On-Board Charger
▪ Various types of e-machines for axle ▪ High peak power up to 300 kW ▪ Large portfolio to cover PHEV, BEV & ▪ Wide range of chargers for charging
drives, hybrid applications, starter Premium BEV with a common voltages from 200 VDC up to
generator and range extender ▪ Low weight (< 120 kg), compact and platform 920VDC
efficiency optimized design
▪ Motor portfolio extension to electrical ▪ Automotive qualified inverters for ▪ OBC portfolio extension up to 22kW
exited synchronous machine (EESM) ▪ System safety concept ASIL D 400V batteries, compatible to 800V power core
▪ Easy customer specific adaption for ▪ Customer specific software ▪ Optional integration of DC/DC ▪ Compact design and a high level of
motor designs integration possible converter mechatronic integration
Technical specifications Technical specifications Technical specifications Technical specifications

Peak power 26 - 300 kW Power range 75 - 300 kW Power range 60 - 300 kW Output power 7,2 - 22 kW
Peak torque up to 600 Nm Torque 2.000 - 6.000 Nm Voltage range 210 - 920 V Char. voltage 200 - 920 V
Rotation speed up to 18.000 rpm Rotation speed up to 1.850 rpm Current range up to 1.300 A Input power 85 - 275 V, 45-65 Hz
Efficiency up to 95%
Efficiency up to 96% Volume 1 - 9.2 l Efficiency up to 96%
Inverter 3ph: 300 - 650 A
Power density up to 6 kW / kg 6ph: 2x650 A Efficiency up to 99% Power density up to > 1.7 kW/l
We are a global company with several sites in Germany, France, China, …
VSeA sites and plants
R&D
Production
Bad
Neustadt Czechowice
Cergy Tianjin
Erlangen
Changzhou
Veszprem (BSAES)
Shanghai Changshu
Shenzhen
Europe Asia OBC related sites
Reorganisation - VSeA and PES goes to PEM (Powertrain Electrified Mobility) - July 3rd/2022
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
Introduction to OBC products
From Combustion engine to Electrical Vehicles
Hybrid
Combustion
Full-Electric
Plug-in Hybrid
* Source: U.S. Department of Energy
Power Devices in Electric Vehicle
What is an OBC ?
AC Grid
Battery charging time is related to
1phase charging power and battery size
3phase
PHEV
OBC battery
BEV
• OBC is the interface between car and public grid

• OBC converts energy
acceptable
• from network grid AC source to DC voltage of car HV Battery charging
time range
• in respect with the public grid and regulations
• OBC is applicable for slow charging use cases
What are OBC and DCDC ?
Higher complexity than special OBC/DCDC
eMotor inverter competencies
international grid utility Battery 400V/800V
comply to all EMC / safety standards galvanic isolated
high frequency switching PFC converter high frequency switching DCDC converter Knowledge and experiences
needed in:
• switch mode power supply
development
• public grid applications
• international standards and
regulations for EMC and
safety
• control software for high
frequency switching
applications
Software control and communication • applicative software for

4...6 different high frequency switching control loops communications with
communication to all international charging stations
protection against hacking (cyber security) different charging stations
(PLC, CHAdeMO, GB/T)
OBC/DCDC is more complex than eMotor inverter, non automotive competencies for grid applications are mandatory
Conductive Charging Modes
Slip forward Restricted area of

contact application
Forbidden in the Opportunity Wallbox / DC / HPC Wireless

most European AC-Charge at any Charging Station Charging Station Charging
Countries , North household socket AC-Charge
America, Canada * Source: World Electric Vehicle Journal
CCS Charging - Combined Charging System - AC and DC charging
AC
DC
AC vs. DC charging / 400V vs. 800V battery voltage
AC charging DC charging
• The car battery is connected • The car battery is directly
via a charger (on board or off connected with a charging station
board) with the public grid • charging equipment is inside the
• slow charging procedure due to charging station
grid limitations (3,6kW….22kW) • fast charging procedure
(50kW…>400kW)
→ charging everywhere via
access to public grid → charging not everywhere, DC
e.g. at home or at public areas charging station needed
(supermarket, parking area, etc.) e.g. at the highway or at public areas
AC vs. DC charging
OEMs goal
400V battery voltage “The time to recharge a car battery up to 80% should not be 800V battery voltage
• state of the art longer than 20min” • currently only in premium cars
• charging infrastructure • charging infrastructure not available
available → 800V battery will be mandatory for BEVs and there for B • charging power > 400kW
• charging power limited to max. and C segment cars • half charging time as with 400V
200kW
Bidirectional Charging and Benefits
Future demand on OBC functionality

is the bidirectional transfer of energy
→ Vehicle to Grid (V2G)
• Use Car’s batteries to store energy

production during low energy demand
period and to stabilize the grid
• Use Car energy in order to cover peak

energy demand -> economy saving
(reduce energy provider invests) and
generates revenues for final customer
• Next Gen of OBC will increase

added-value for customers. Cars with
Bidirectional feature lead to additional
services and biz modells.
Bidirectional Charging and Benefits V2L - V2V
V2L : Vehicle to Load
▪ Can be used to supply an electric consumer with the battery of the car (TV,
computer, barbecue, rice cooker, fans…)
▪ By extension, we can consider all products used by a craftsman or worker when
acting away from a grid network (then, no need of a diesel generator)
▪ No communication needed, just consumption by a passive load
V2V : Vehicle to Vehicle
▪ By extension, with additional improved control quality, one potential load could be
another charger of a car (in order to recharge the battery of this second car (like jump
start))
▪ In this arrangement, a charger will be supplied by another charger and
communication could be needed but not mandatory
Bidirectional Charging and Benefits V2H - V2G

V2H : Vehicle to Home
▪ When it comes to a large amount of devices to be supplied, then we are

not far away to supply a complete home.
▪ A battery from a BEV is able to supply a home for a day long.
▪ In order to manage supply from vehicle and from grid, an energy
supervisor will be required and communication is requested from vehicle.
With a good cybersecurity behaviour.
V2G : Vehicle to Grid
▪ Propose a large energy storage at grid level (alternative to stationary

batteries) and helps to optimize renewable energy usage/ limit use of
thermal power plant
▪ Use the energy stored in the cars to supply the energy consumption load
during the day
▪ Use the smart chargers to enhance quality of the grid and provide
frequency regulation
▪ Extensive communication is needed, it will always go through a charging
station, monetization will be part of the process, cybersecurity is
mandatory
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
OBC Market Trends and Competition
Why is electrification coming?
Climate Change
• 2012: highest CO2 concentration in the atmosphere for 800,000 years

• 2001 to 2010: warmest decade on record
Growth of cities
• 1975: 3 megacities with more than 10 million inhabitants

• 2025: 27 megacities with more than 10 million inhabitants; roughly one in ten people live in a megacity
• 2050: 70 percent of mankind will live in cities
Future of energy
• 1990 to 2009: global trade volume more than doubles

• Fossil fuel resources are becoming scarcer
• Increasing focus on renewable energy
The CO2 regulation is the main market driver
China:
5.0 l/100 km
EU:
4.0 l/100 km
Worldwide regulations are converging and at the same pace CO 2 solutions will be global.
On-going city pressure to clean-up inner city air pollutions
Paris, Madrid, Athen London Berlin

and Mexiko City
agreed to ban diesel vehicles from the center of their
cities by 2025
C40 introduced a special toll in
2017, which affects gasoline
and diesel vehicles with
evaluates driving bans for diesel
(possible starting year: 2019)
Euro 3 or lower
Cities München
examines adding new minimum
standards for nitrogen dioxide to the
existing environmental zone
Madrid Paris
introduced a driving ban on Euro 3 diesel is already excluding Euro 2
in 2020, to be extended to Euro 5 diesel diesel and Euro 1 petrol
in 2024 (applies nationwide) engines during the day Oslo And
wants to enforce a general ban on private cars with
older generations of combustion engines in 2019.
many
Exceptions should only exist on large thoroughfares. more…
Status as of June
2018
The political leaders that make up the C40 group of global megacities are all
taking steps to crack down on diesel vehicles and reduce smog
Market segmentation and growth
Cars (in mn) < 6t
From 2.2% to 27.9%

Electric / Fuel cell
From 3.3% to 14.6%

HV Hybrid
From 40.2% to 52%

Stop-Start & Mild Hybrid
From 54.3% to 5.5%

Conventional
Market - High Voltage Vehicle Volume Growth (vehicles < 6t)
Mio Unit
High Voltage Vehicle Volume Growth
Product portfolio
eMotor FCEV: Fuel Cell Electric Vehicle
Inverter BEV: Battery Electric Vehicle
Rear eAxle EREV: Extended Range Electric Vehicle
PHEV: Plug-In Hybrid Electric Vehicle
Front eAxle R FHEV: Full Hybrid Electric Vehicle
CAG
%
On-Board +21
Charger/DCDC
2021 MTP, SPP
High Voltage vehicle market will account 42% share in 2030 for total Automotive market (+2.5% vs. ‘20)
ICE ban > 2030 as catalyst for further electrification
OBC Product and Market Trend
Technical trends 2020…2030 Market Price year 2025 OBC Customer addressable
Cyber security
Power density
(SiC/GaN) M
B
Addressable
Combo
Bidirectional
Non Addressable
M
800V
2020
Major Trends are clear, VSeA can meet the Target Prices. OBC will remain a buy product in growing2030
BEV market.
Competitor Benchmark ✔in development Market Share Adressable Market VSeA 2021 Customer portfolio
Product Portfolio Combo Bidir Power Density Price VSeA VSeA Identified customer for
96M€ advanced
11kW 22kW 800V 7kW 11kW
568M€
development
VSeA ✔ ✔✔ ✔ ✔ ✔ ✔
Kostal
Delta 2021 2030 Other current

Customers
1.5B€ 8.4B€
Meta
Shinry
Data reference: 2021 MTP
With Gen 4 OBC VSeA has the Right Product inTime for the Wave 2
Competitors overview
Who are the competitors 2020 2025

3.5Mio 11.5 Mio
• Kostal
• Delta
• Meta
• Panasonic
• Lear
• Shinry
VSeA Market Share Analysis of Addressable market, exclude Tesla and Toyota,
Marklet data PWT 0326
There is no absolute Leader on OBC market. Kostal and Lear are the strongest competitors today.
Panasonic is starting to extend out of JOEMs
Market trends
Power segmentation: flexible solutions for different car segments / regions

PHEV (7,2kW - 11kW), BEV (11kW - 22kW)
Europe (11kW - 22kW, 1/3phase)
Asia (7,2kW - 22kW, 1/3phase)
NAR, JPN (7,2kW - 22kW, 1phase)
EVSE HV
Reversible OBC function, V2X compatibility
400V 800V
: ... Compatibility for 400V and 800V battery types
kg Vol
Size and weight reduction, power density increase, target >1,7kW/L
Combo integration: 2in1, 3in1....6in1
Which Product and volumes per Region
AC Grid CCS2 GB/T AC CCS1

System 1/3phase connection 1/3phase connection 1phase connection
Connector comm. via PLC comm. via GB/T-ChaoJi comm. via PLC-CHAdeMO all variants
2020 2025 2030 2020 2025 2030 2020 2025 2030 2020 2025 2030
AC Charging
Power
Charging
direction
percentage values based on existing RFQs and market investigations by regional customer interfaces - values for 2030 mostly based on market investigations and estimations
The table shows the regional differences and demands, RFQs from OEMs will usually reflects all different variants
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
OBC History, Roadmap & Portfolio
VSeA OBC History of Generations
GEN 1 GEN 2
• Automotive application in 2010, based on existing
• Best-in-class charger for size, volume, weight, and
telecom & industrial design
efficiency in the market
• Compelling and industry standard setting HE (High

• Fully automotive. Designed, tested and produced
Efficiency) technology
compliant to new market & VDA specifications, using
automotive components
• Design reinforced to meet automotive requirements for
vibration, shock, humidity, dust, salt spray, and
• Flexible design platform. Easily repackaged to match
extreme temperatures
customized OEM-specific form factor, signal interface,
and software requirements
• Higher output voltage than telecom standard, two
different housings as standard products; Signal
• More elaborate communication interface, wider output
interface with CAN-bus only
voltage range (up to 450VDC) and more power
(3.5KW)
• Efficient production due to long-standing production
partner in China
• SOP 2015
• SOP 2013
GEN 2.5 GEN 3
• Best-in class charger for performance and volume • Charger with optimized process features and cost
compromises in the market. offering excellent competences on the automotive
market, especially for high volume production.
• Cost effective solution compared to GEN2 with
simplified PFC stage and integrated magnetic blocks. • Increased output voltage up to 470V.
• Various versions supporting 11kW three phase • Integration of newly developed power module
charging and 7kW single phase charging. especially for OBC application
• Support various charging standard: Chademo, PLC… • Development completed
• Successful products with 25% market share together • Transfer to GEN4

with Gen2.
• SOP 2017
GEN 4
Full product family with platform approach of re-usable building blocks. Power range 7kW/11kW/22kW
Worldwide compatibility
1 platform to address all cars and countries requirements
400V or 800V batteries, 1/3 phase network
Modular design approach

Platform approach to create different Combo variants based on different
OBC/DCDC building blocks
Scalable design
Several power and voltage variants for OBC and DCDC can be combined to
create customized products
New Bidirectional Functionality

for a sustainable integration of battery vehicles in smart grid network
maximize the development of renewable energy sources
OBC Roadmap
22 kW
GEN4
800V/bi-dir V2x SiC GEN4
400V/bi-dir V2x
All platforms are worldwide available Eu and CN
11 kW
GEN2.x
400V/mono-dir GEN3
400V/mono-dir GEN4
400V/800V/bi-dir V2x
7,2 kW
GEN2.x
400V/mono-dir
GEN2.x
400V/bi-dir V2L GEN4 Combo GEN4+3kW
GEN4
Combo 2in1 / 3in1 400V/bi-dir V2x DCDC 400V/bi-dir V2x
400V/bi-dir V2x
40…80kw
Gallium Nitrite
3,6 kW
LEV
GEN2.x
400V/mono-dir
several variants 400 / 800 V Range:
Optimized Efficiency & Packaging Int.
SOP
2019 2020 2021 2022 2023 2024 2025 2026 Dates
GEN4 as platform product for all new RFQs / Nominated end of 2021 by a big EU OEM
Mass Production Advanced
Stopped Project Innovation
OBC Range
GEN2 GEN2.5 GEN3 GEN2.5 GEN4
CUSTOMER REQUIREMENTS
Power 3,5kW 3,5kW 7kW 11kW 11kW 7kW 7kW 11kW 22kW
170-470V
Battery Voltage 170-420V 170 - 450V 220-470V 170-450V 170-470V 600-920V
600-920V
Infrastructure 1phase 1+3phase 1phase (V2L) 1phase 1+3phase 1+3phase
Mode Monodirectional Bidirectional
TECHNICAL SPECIFICATIONS
Architecture 1 cell 3 cells 1 cell 1 cell 1 cell
PFC Tri phased PFC

Totem pole PFC
Topology bridgeless + Standard PFC + LLC converter Totem pole PFC +LLC converter + tri phased LLC
+ LLC converter
LLC converter converter
Mass
SOP mid China SOP Mass SOP mid
Devt. Status production SOP 2020 SOP 2024 SOP 2024 SOP 2024
2019 mid 2019 production 2021
since 2015
Vehicle integration
OBC Gen2 Volvo OBC Gen2 BMW
• 3.5 kW, SOP 2013 SPA platform • 3.5 kW, SOP 2015 35up platform
• XC 60, XC90... • 3, 5 and 7 series
* Source: Volvo * Source: BMW
Vehicle integration
OBC Gen2.5 RSA OBC Gen2.5 LEVC
• 3.5 kW, SOP 2019 5DH platform • 11 kW, SOP 2016
• Clio, Capture, Mégane • London Taxi Cab
* Source: RSA * Source: LEVC
Vehicle integration
OBC Gen3 Rivian (lost project)
• 11 kW, SOP 2021
• R1T
* Source: RIVIAN
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
OBC Technical Specification & Architecture Overview
Overview of Platform approach based on building blocks
Fix features product Covered by P2
- Architecture and Topology

- Semiconductors (Type and Package)
- Magnetics design Standard feature fully reusable
- Internal power supply
- Control law (PFC / LLC)
- Internal communication (CAN / SPI)
Variable features Covered by P2 - adapted in P1

- Mechanical integration
- Connectors
- OBC reverse power
- DCDC power
Variable feature upgrade / modify
- Sensors
- uni/bi-directionality
- Gateway functions
- Diagnostics
Specific features Customer specific - P1

- Gateway software
- Customer specific functions and features
Not existing new feature
OBC GEN4 and Combo - Overview of Building Blocks
7kW OBC 11kW OBC 22kW OBC Common OBC
7kW OBC GEN4 architecture 11kW OBC GEN4 architecture 22kW OBC GEN4 architecture primary PFC uC
7kW AC input filter 11kW AC input filter (1+3phase) 22kW AC input filter (1+3phase) PFC control law
7kW pre-charge function 11kW pre-charge function 22kW pre-charge function LLC control law
7kW PFC stage (bi-dir) 11kW switch matrix 22kW switch matrix secondary LLC DSP
7kW FB CLLC stage (bi-dir) 11kW PFC stage (bi-dir) 22kW PFC stage (bi-dir) internal isolated SPI
7kW transformer (400V) 11kW FB CLLC stage (bi-dir) 22kW FB CLLC stage (bi-dir) internal isolated CAN
7kW rectifier stage (bi-dir 11kW transformer (400V) 22kW transformer (800V)
400V) 11kW rectifier stage (bi-dir 400V) 22kW rectifier stage (bi-dir 800V)
Gateway
7kW DC output filter (400V) 11kW DC output filter (400V) 22kW DC output filter (800V)
internal power supply
Combo / DCDC Mechanics Gateway uC
Combo architecture Mechanical architecture external CAN FD
3kW DCDC input filter HV AC Connector Pilot signal
3kW DCDC FB phaseshift HV DC Connector Proximity signal
3kW DCDC transformer Signal Connector Locking motor
3kW DCDC syncronous rectifier Water cooling spigots LED control
3kW DCDC output filter Cooling channel sealing Wake up
DCDC control law Product sealing Diagnostics

CHAdeMO
PLC
P2 OBC GEN4 and Combo contains a sum of >50 building blocks which can be re-used for all future
P1s PNC
OBC GEN4 and Combo architecture based on building block approach
OBC Private CAN
GALVANIC
Isolated
Gateway
INSULATION
Primary µC power GW µC PLC SBC
(PFC management & LLC Secondary µC supply TC3xx Chademo CAN Signal
control law) PFC Control Connector
(PWM management) Chaoji IOs
TC364x law
LLC Control
Sensors Drivers law Drivers Drivers Sensors
DCDC
DC
EMC Filter LVDC
AC Input OBC/DCDC filter
EMC
AC filter
Input
EMC filter
7kW
11/22kW
PS input Output Safety
Transformer
stage Rectifier Switch
PFC 7kW CLLC 7/11kW Transfo 7/11kW Rectifier HVDC LV
HVDC
PFC 11/22kW
PFC 7kW CLLC
CLLC22kW
7/11kW Transfo 22kW 7/11kW
Rectifier Connector
HVDC Conn.
Transfo 7/11kW Connector
PFC 11/22kW CLLC 22kW Transfo 22kW Rectifier 22kW
7/11kW Connector
Rectifier 22kW
HVAC
HVAC
Connector
HVAC
Connector
Connector
Product Architecture is fully following the platform approach and based on common, re-usable building blocks
OBC GEN4 – Main Characteristics
Items 7kW (1ph) 11kW (1/3Ph) 22kW (3ph)
AC input voltage 85-275Vac 85-425Vac (3ph) 85-425Vac (3ph)
AC input frequency 45-65Hz 45-65Hz 45-65Hz
16A max (3ph) 32A max (3ph)

AC input current 32A max
48A (1ph) 96A (1ph)
Power Factor 98% @ > 20% load (IEC 17409) 98% @ > 20% load (IEC 17409) 98% @ > 20% load (IEC 17409)
Efficiency > 96% peak > 96% peak > 96% peak
DC output power 7200W for Vout > 280V 11 kW (800V and 400V version) 21 kW (800V and 400V version)
Nominal range : 550 – 870V (800V output Nominal range : 550 – 870V (800V output
Nominal range : 280 – 470V
version) (920V max) version) (920V max)
DC output voltage Extended range (derating) : 200V –
Nominal range : 280 – 470V (400V output Nominal range : 280 – 470V (400V output
500V
version) version)
40A max (400V version) 80A max (400V version)
DC output current 26A max
20A max (800V version) 40A max (800V version)
Coolant: -40°C - 65 °C Coolant: -40°C - 65 °C (75°C with derating) Coolant: -40°C - 65 °C (75°C with derating)
Temperature
Ambient: -40°C - 85 °C Ambient: -40°C - 85 °C Ambient: -40°C - 85 °C
Package 4,8 liter 9 liter (TBC) 11 liter (TBC)
OBC GEN4 – 11kW Efficiency
Conditions:
25°C cooling, 230V 3-phase charging only - SiC MOSFET for PFC/LLC/Rect.
OBC GEN4 – 11KW Derating strategy
• Full power between Vout = 290V...470V
• Power limitation because of max. Output current between Vout = 200V...290V
OBC GEN4 – Control Architecture
Combo architecture:
- Based on GEN4 OBC

and DCDC
- Merged housing
- Merged DC filter
- Merged control
- Merged internal power

supply
- Merged Gateway
OBC GEN4 – Software Architecture
GW+ DCDC MCU SW:

CAN LIN
- Communicates with the Vehicle and the OBC Powerstage
Gateway + DCDC
- Storage of DTCs
- Diagnostic handling UDS, OBD
- CCP handling
- Network management.
- Control of the DCDC phase shift GW +
- Bootloader master + OTA management. DCDC
- Cyber security master.
- Wake-up sources monitoring through the SCR processor (SCR processor included in the Aurix package)
PFC MCU SW:

- Communicates with the Gateway MCU SW and LLC CAN
- Control the PFC and LLC + Driver PFC
OBC Powerstage
- Control the current, temperature, voltage and power regulation
- Controls all switches and grid connection
- OBC powerstage diagnostic master
PFC
LLC MCU SW:
- Communicates with PFC MCU SW
SPI
- Driver LLC
- Pilot the switch of the LLC powerstage
- Diagnostic of its defects (SPI communication/overcurrent/overvoltage) LLC
Software architecture defined & development

07.04.2022
Restricted © Valeo Siemens eAutomotive 2022
according to A-SPICE L2 as target
PL - PE R&D RFQ & ST OBC / J. Schulz Page 50
OBC GEN4 – Gateway Software Architecture
VIN SysTime Darh Coding Pia Omc Stm Wur Rmh ObdM
StdDiag Dlog Fscsm Auth Edch Cbs Swt PnDm PnS

MAIN TSK LAYER
CarbDia ResetHa ChargeC Charge Codi. Deratin Dlog_Us DlogWr WUPdet Can Sig.
OBD WDG FSM DIAG
g ndl trl Mon Wrap. g er apper ect Map.
Autosar RTE
BootLoader OS System Services Diagnosis Memory Communication Services Complex
Services Services Drivers
EcuM Det Nm PduR

OS
NvM
BswM ComM Com IpduM

Dem Srv
MemIf
WdgM HAL DCM CanIf BUtil

CanNm
Autosar
Fee
Library
IOHAL
WdgIf CanTp CanSM XCP SafeTpa
fls
Crc ck
MCAL EXT
Wdg Pwm Icu Fls ADC Pilot
Cpl
Proxy
BUtil Spi Mcu Gpt Dio Port HLP FBL Can RamTst CanTrcv
Custom
Infineon Vector VSeA Hitex ?
er
OBC GEN4 – PLC (Power Line Communication) Architecture
Without PLC functionality With PLC functionality
EVSE Gateway EVSE Gateway

PLC power supply WUP
CC/CP Aurix TC364 CC/CP PLC PLC Aurix TC375

Filter chip
+
Transfo
- Extended uC for full gateway

- Standard uC for light gateway - HSM module (incl. full EVITA support)
- HSM module not used - Complex wake up (additional wake up sources coming from EVSE by using PLC)
- Simple wake up - PLC chip, incl. Peripherie (filter, transformer, power supply)
- no PLC software - PLC software acc ISO15118
- PnC software acc ISO15118
OBC GEN4 – Interfaces - Gateway
• Meet explicit SW architecture standard requirements. For example
AUTOSAR, CAN protocol, etc.
• Interface the OBC with car by CAN.
• Pilot signal (SAE J1772 and DIN EN 61851 standards) = Detect
charging level required battery
• Proximity signal (SAE J1772 and DIN EN 61851 standards) => Detect
type of electric grid and its power level
• Sleep and wake-up functionality => Make OBC wake up or sleep
• Diagnostics (OBD)
• Communication with power stage CAN
• Software download via CAN
• I/O functions
• LED management RSA 5DH 3.5kW Gateway
• HV interlock detection
• Charging flap and socket motor drive
• Internal temperature measurement and power derating
• External temperature sensors
• Chademo for fast charging
• PLC and PnC (Plug & Charge) VW MEB 11kW Gateway
GW comparison (transfo for scale)
• LIN (as option)
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
Power Factor Correction
PFC
Why need PFC? A device connected to electric grid has to respect the following:
1. Consume a SINUSOIDAL current. 2. Assure that the Sinusoidal current is

PFC 7kW
Expressed on Total Harmonic Distortion (THD) or in phase of the grid voltage. PFC 11/22kW
Harmonic power factor (HPF) Expressed on displacement Power Factor (DPF)
With PFC Without PFC
Yes No
Consequence of too low PF
PC load
PFC 7kW
PFC 11/22kW
Domestic 16A .
Resistor Load
Bad management of the Power Factor by the product will directly affect I in consumption
PFC topology
PFC role is to maintain the input

current waveform to be in phase with PFC 7kW
PFC 11/22kW
the input voltage.
And also provide a suitable DC input

Switch on
voltage for the DC/DC stage.
Switch off Outputs controlled

by duty cycle.
PFC Operations
Key is an operation of a boost converter,
regulated by duty cycle D.
Vdclink
PFC 7kW
Vboost PFC 11/22kW
Switch on
Switch off
Boost converter can only boost

output voltages higher than input.
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
Resonant Converter and LLC
Why an extra DCDC stage with Isolation?
Example non-isolated OBC

Replace galvanic isolated LLC by buck converter (picture showed 7kW)
CLLC 7/11kW Transfo 7/11kW

CLLC 22kW Transfo 22kW
Non
isolated
BUCK
Operation Constraints Safety Constraint

- The PFC gives an output voltage with - Could lead to safety risks because of
big 100Hz ripple (30Vpk-pk) => Difficult missing galvanic isolation.
to charge directly battery.
- Battery Ground is linked directly to the
- Need a DCDC stage to get a smoothed electrical grid.
charging voltage & current.
Why Resonant LLC DCDC Converter ?
Charging mode:
Q9…Q12 working as
H-bridge input stage for
LLC CLLC 7/11kW Transfo 7/11kW
CLLC 22kW
DC DC
Transfo 22kW
Q13…Q16 working as
output rectifier
Reverse mode:
Q13…Q16 working as
H-bridge input stage for
LLC
Q9…Q12 working as output
rectifier
Resonant Loss 100% ZVS, Very low losses and high efficiency
Converter Semiconductor Ratings No voltage spike seen by the rectifiers & MOSFETs, no overshot risk
Advantages
Topology No filter inductor, less component
Transformer Small Transformer Size
Output Syncronous Rectifier
Syncronous rectification
Alternating voltage Rectifier
and current out of HF AC DC

7/11kW
Rectifier 22kW
the transformer
Pure DC output current
Capacitive Filtering:
A first stage filtering absorbs the sinusoidal ac current
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
Bidirectional Function
Bidirectional OBC Charger Development
Bidirectional PFC Bidirectional DC/DC
OBC
GEN 2.x (SOP 2020) GEN 4 (SOP 2024)

NEXT STEP
V2L: 7kW V2X: 7kW/11kW/22kW
Bidirectional Function
Bi-directional function – Modifications, shown on OBC 7kW as example

7kW Monodirectional
OBC
Removed
4 diode
PFC MOS increased to 4pcs Add a resonant cap 4 Diode changed into MOS
7kW Bi-directional
OBC
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
Hardware Design
Transformer Design in OBC
Safety:
Comply insulation
prim. Vs sec Heat:
Leakage:
No hot-spot
To be integrated to
T<130°C
simplify design
Good Transformer
Process:
Easy to mount Efficiency:
avoid cracks Good efficiency
η>99%
Parasites:
To be minimized to Core:
optimize EMC Material: Good core set to
Carefully selected avoid saturation
for loss reduction
Hardware Design
Magnetics Optimization GEN2 to GEN4
No.
VOUT Max Figure of magnetics in product Size Cost 2020
Magnetics
GEN2
410V 5 100% 15.7€
Separated
(reference)
magnetics
GEN2.5
430V 4 84% 11.9€
CHINA
GEN2.5
Europe
450V 3 75% 12.8€
Integrated
Magnetics
GEN3/4
Ultra-Integrated 470V 2 54% 11€
Magnetics
Hardware Design
Simulation platform on Simetrix
• Architecture: Understand the operation of the power electronics system.
• Pre-design: Current & voltage on capacitors, magnetic, semiconductors…
• Standard simulations integrated to Valeo databases with continuous updates.
Hardware Design
DC Link Capacitor - Electrical sizing
Use simulation platform & calculation:
To extract of current waveforms to get total ripples from

PFC stage and LLC stage.
HW Inputs
-Maximum voltage stress: 435V.
-Maximum current stress (Worst case operating point regarding DC Link capacitors
current): Output power 3.6kW, Output current 12A, DCLink voltage 340V.
-Maximum Capacitor RMS current: 6.4A per capacitors (case 2 capacitors in
parallel)
- Product Lifetime requirements…
- Calculation of DC Link Capacitor Power Losses
Hardware Design
DC Link Capacitor – MK Integration
Inputs
- Material and thickness of the thermal exchange area:
- Potting TIA 216 G – 3mm
- Casing aluminium – 4mm
- Cooling type: 40% Water – 60% Glycol
- Minimum cooling flow rate: 2L/min
- Water temperature distribution
Rth Outputs between case and water :

⇒ Rth_case-water = 1.64 K/W*
*Hypothesis:
- Dissipation only from the top of the capacitor (since the water is only on the top)
- Diffusion angle 45°
Obtain Capacitor Mission Profil :
- Based on the OBC Product mission profile and losses predicted.
Hardware Design
DC Link Capacitor – Build Supplier Proposal
SPECIFICATION to supplier DEFINITION from Supplier to VSeA
• Rated Voltage @ Dclink stage 450V • 2 capacitors in parallel
• RMS Current @ Dclink stage • 680µF Aluminum electrolytic capacitor
• Ripple Voltage 35V • Acc. to life time requirements, EPCOS/TDK

estimates 26% of life time is consumed with two
• Lifetime 15000h with profile specification
capacitors in parallel.
• Capacitor Mission profils.
• Simulation result, Voltage Ripple = 32V <35V
•…
Hardware Design
Semiconductor Package Evolution
GEN2.5 GEN4
Through hole components Integrated components
PFC 7kW CLLC 7/11kW Transfo 7/11kW

PFC 11/22kW Rectifier 7/11kW
CLLC 22kW Transfo 22kW Rectifier 22kW
3.5kW 7.2kW 11kW - Key Benefits

- Strengths 7,2kW 11kW 22kW
Bridge 1 2 3 - Improved cooling concept
-Well-known PM 3 3 3
- Higher Compactness
technology Diode 5 10 15
IGBT 2 2 2
- Easier assembly
MOS 6 12 18
- Less mechanical parts
-Weaknesses
- Standard component
-Cooling
-Assembly
-Technical Risks
- High thermal density inside module
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
Product Mechanical Integration
Packaging evolution
Gen2 - P1 Gen3 - Stopped Gen4 - P1 Gen4 - RFQ
OBC Volvo 3.5kW OBC BMW 3.5kW OBC Rivian 11kW OBC BMW 11kW OBC 11/22kW DCDC 3.5kW Combo
Dim: 304.9 x 194 x 68 mm Dim: 400 x 200 x 68 mm Dim: 487 x 337 x 93 mm Dim: 800 x 310 x 65.1 mm Dim: 400 x 307 x 109.5 mm
2015 2021 2024 2025
2015 2020
Gen2.5 - P1 Gen4 - P2
OBC 7kW OBC 22kW OBC 7kW DCDC 3kW Combo

OBC LTC 11kW OBC RSA 3.5kW
Dim: 394 x 280 x 95 mm Dim: 443 x 346 x 125.6 mm Dim: 443 x 346 x 125.6 mm
Dim: 362.7 x228.2 x 115.5 mm Dim: 241.5x200x121.4 mm
Architecture definition
Matrix Choice is done to find best compromise with several criteria based on the following items
• MK integration
• Process
• Purchasing
• HW Layout
Architecture overview
GEN 4 Combo integration - 22kW 800V
DCDC Cover
AC Filter Board
Aluminium
Shielding
GW/DCDC Board
HVDC Filter Board

HVAC Connector
Spigots
LVDC Connector
Cooling Cover
Signal Connector
OBC Power Board

HVDC Connector
OBC Cover
Aluminium
Architecture overview
Concept
● 11kW & 22kW have same dimensions
● Same external package (housing & covers)
● Same connectors ref & location
● Same GW/DCDC Board
11kW
Advantages regarding Customers

● Synergy between teams
● Product integration consistency
● Huge mechatronic Integration work for:
○ Optimized BOM cost
○ Optimized process line
○ Optimized EMC/HW management
○ Optimized thermal management 22kW
Reuse parts & concepts

BOM Cost optimisation
● Integrations are done to optimize direct BOM cost by reusing parts & concept between projects
● Example of reuse on 11kW combo & 22kW combo projects
Parts reuse Concept reuse

Same external dimensions
Housing - Same fasten area location
Same connector location
Covers OBC Cover
Same board assembly process
AC Filter Assembly Board HVAC Power Interconnector
Same Shielding concept
HVDC Power Interconnector
DC Filter Assembly Board Same board assembly process
Shielding
OBC Assembly Board Discrete component’s clamp Same board assembly process
Complete DCDC equipped board
DCDC / GW Assembly Board Same board assembly process
Discrete component’s clamps
Same HVAC, HVDC, Signal & LVDC
Connectors Same location on the product
Connectors
Potting references
Chemical Thermal pad references -
Cover seals
Miscellaneous Dielectric Foils -
Process Same tooling carrier Same process flowchart
Reused parts
Sealing
Friction Stir Welding techno for cooling sealing
FSW Process done by die casting supplier

VSeA OBC
● Parts machined after FSW process to ensure tolerances quality 2015 SOP
● Leakage test performed by supplier before VSeA reception
Robust design
● FSW Cooling concept with premium european OEMs
○ 610K OBC since 2015 without major issues
P2 Concept
VSeA Combo
prototype
* Source: RIFTEC Hai-Gruppe Channel

FSW process 100% tested by supplier to insure best quality
Design For Manufacturing
P1 Issue illustration Gen4 solution illustration
3D rubber gasket (for signal 2D sealing glue (signal connector

connector) inserted in another assy step)
Wire connection for HV HV connectors with leadframe

connectors inserted on inserted through sockets from PCB
screwed busbar Connector
Potting in heatsink / Gap pad

on casing - strength Potting in housing cavities
measurement
Heatsink assembly for

mosfets: clips, insulating foils,
Soldered Power modules
plastic holder - strength
measurement
Gap pad / wire connection suppression - heatsink replacement by power module
Vibration Behaviour
VSeA OBC in serial production
● LV124 specification
○ Vibration profile D (hang-on parts (for
components installed on sprung masses)
● The test is performed on the basis of ISO 16750,
● The test is carried out as per DIN EN 60068-2-64
for wide-band vibration excitation
Other profile applied on OBC

● ISO 16750-3
○ Test IV - passenger car, sprung masses
(vehicule body)
● According DIN EN 60068-2-64 random vibration
● The r.m.s. acceleration value shall be 27,1 m/s2
VSeA OBC testing
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
Thermal Management
Internal cooling channel
● Best Cooling/Integration compromise
● 3D cooling channel
● Closed by FSW Cover
● Optimized to cool down dual side integration
Thermal compounds
● Gap filler / Thermal Pad
○ Powermodules
○ Diodes / Mosfets
● Thermal Conductive Potting

Extracted 3D
○ PFC Coils
Cooling Channel
○ Resonant inductances
○ Transformers
○ AC/DC Filter chokes
OBC Thermal Management
Thermal behaviour - Cooling strategy
Semiconductors @Max power / 85°C / 65°C cooling Magnetics @Max power / 85°C / 65°C cooling
Function Component Picture Thermal Status Status Function Component Picture Thermal Status
block interface 11kW 22kW block interface 11 & 22
PFC Module <175°C <175°C

OBC PFC Choke <130°C
Thermal
OBC LLC Module <175°C <175°C Power
grease
Power Board Transformer <130°C
REC Module <175°C <175°C
Board
Cavity in
Discrete semi DCDC
Insulated <120°C <130°C Transformer / Housing
conductors Power <120°C
thermal Choke +
Board
Discrete semi foil Potting
<120°C <120°C
DCDC conductors
AC Filter CMC Choke <110°C
Power
SR Mos <140°C <140°C
Board Gap filler
DC Filter CMC Choke <130°C
Safety Mos <115°C <115°C
Complete thermal modelling and correlation must be done, as Power Module methodology
Product Thermal Integration & Validation (PM Focus)
x3 same Power Modules package for PFC, LLC and Rectifier functions
➔ Soldered on Power Board
➔ Direct screwing on Housing to insure best TIM thickness
➔ Cooling channel with integrated pinfins
Thermal grease
10W/mK,
Theory max 50µm
Measured max 10µm
Simple integration to reach best thermal

Industrial concept with soldering of components at a controlled distance : performances with basic features
➔ to insure same position / coplanarity and same thermal behaviour along production
➔ to reduce stress in solder joints
THT solder jig (Housing representation) Contact plane between PM/TO and jig
Potential slot
design to reduce
residual solder
Controlled stress
distance
Product Thermal Integration & Validation (PM Focus)
Simplified waterbox created to measure real Rth and correlate thermal model
Theoretical inputs Measurements
Rth measured on 11kW LLC

LLC layout Power Module
Correlation
accuracy ±5%
PM : 22kW PFC
Power losses: 65W
Q : 6 l/min & Tinlet : 65°C
4 5 6
K:10 W/m.K & TIM 0.05mm
1 2 3
Model correlation show that 22kW PFC performance will be achieved
Comparison with previous generations
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
Manufacturing Process
PCBA Board preparation Process
● AOI Test: Automated

visual inspection
scanning missing
components or quality
defects.
● ICT/FCT Test: Check
basic quantities to
detect if fabrication is
correct.
● Calibration test:
Calibrate voltage,
current ratings.
● HI-POT test: insulation
testing for security
purpose.
● EOL test: End of line
test covering overall
functionality of product
Outsourced process Vsea process
Final process assembly
Involved technologies :
Vsea line:
● Screwing
● Dispensing
● SWS process
● Assembly operations
● HiPot Testing
● Leakage Testing
● FCT / Calibration
● EOLT
● Burnin-test
Vsea suppliers process:

● Die Casting
● Friction stir welding
● SMT process
Process line layout example
Board preparation (THT / Coating / FCT) Final assembly
Contents
1 Introduction
3 Power Conversion
3.4 Hardware Design
Product Integration & Validation
Prototype & EV
EV: Characterize
the design and
validate the correct
operation.
Mainboard Functional Test Mainboard Assembly

Filterboard
Mainboard
Gateway
HV AC Header
Functional Bench
For each functions
Gateway Board Functional Test Gateway Board assembly
DV & PV
DV & PV
• Automated testing
• Test report with PASS/FAILED criteria
• Measurements with external sensors ( current - Voltage

probes, Torque sensors, Temp etc..)
• Labview software used for interface
• N.I. Facilities
• Product Monitoring
• COM: CAN / Flexray / LIN

SW platform
• Loadbox ( Gear / Resistor/ Inductance / Stator, Motor etc..)
• Multi channel ( 1 to 6 parts in same time)
• Benches for : Characterization test, Elec test,

Environmental Test, Endurance tests) OBC platform
Our Vision: High Tech cost efficient solutions for high voltage xEV drivetrain systems
And now, you:

● Got knowledge on On Board Charger product
line history, portfolio, functionalities, market
trend and roadmaps
● Should understand key technologies in OBC
design
● Are able to be integrated into OBC projects
quickly after this training
Our Vision: High Tech cost efficient solutions for high voltage xEV drivetrain systems
THANKS FOR YOUR ATTENTION

Owner: Juergen Schulz
E-Mail: juergen.schulz.jv@valeo-siemens.com
Landline: +49 69 2475682 3308
Mobile: +49 176 3000 1308
Trainers: Juergen Schulz

Sébastien Douillard
Sixiong Zhen
Chen He
Platform website: Link

OBC Product Training V04.0

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OBC Product

Valeo contributes Business mandate Siemens contributes

Siemens AG Valeo S.A.

The business: The business:

▪ to design, develop and produce ▪ high voltage applications over 60V

▪ with a voltage level exceeding 60V

▪ for use and installation in passenger cars and light or medium

Motor Integrated Motor System Inverter On-Board Charger

Technical specifications Technical specifications Technical specifications Technical specifications

VSeA sites and plants

Europe Asia OBC related sites

* Source: U.S. Department of Energy

• OBC is the interface between car and public grid

Software control and communication • applicative software for

Slip forward Restricted area of

Forbidden in the Opportunity Wallbox / DC / HPC Wireless

Bidirectional Charging and Benefits

Future demand on OBC functionality

• Use Car’s batteries to store energy

• Use Car energy in order to cover peak

• Next Gen of OBC will increase

Bidirectional Charging and Benefits V2L - V2V

V2L : Vehicle to Load

V2V : Vehicle to Vehicle

Bidirectional Charging and Benefits V2H - V2G

▪ When it comes to a large amount of devices to be supplied, then we are

V2G : Vehicle to Grid

▪ Propose a large energy storage at grid level (alternative to stationary

• 2012: highest CO2 concentration in the atmosphere for 800,000 years

• 1975: 3 megacities with more than 10 million inhabitants

• 1990 to 2009: global trade volume more than doubles

Paris, Madrid, Athen London Berlin

Cars (in mn) < 6t

From 2.2% to 27.9%

From 3.3% to 14.6%

From 40.2% to 52%

From 54.3% to 5.5%

2021 MTP, SPP

Delta 2021 2030 Other current

Who are the competitors 2020 2025

Power segmentation: flexible solutions for different car segments / regions

Reversible OBC function, V2X compatibility

: ... Compatibility for 400V and 800V battery types

Combo integration: 2in1, 3in1....6in1

AC Grid CCS2 GB/T AC CCS1

• Compelling and industry standard setting HE (High

• Support various charging standard: Chademo, PLC… • Development completed

• Successful products with 25% market share together • Transfer to GEN4

Modular design approach

New Bidirectional Functionality

Infrastructure 1phase 1+3phase 1phase (V2L) 1phase 1+3phase 1+3phase

Mode Monodirectional Bidirectional

Architecture 1 cell 3 cells 1 cell 1 cell 1 cell

PFC Tri phased PFC

* Source: Volvo * Source: BMW

* Source: RSA * Source: LEVC

Fix features product Covered by P2

- Architecture and Topology

Variable features Covered by P2 - adapted in P1

Specific features Customer specific - P1

Combo architecture Mechanical architecture external CAN FD

3kW DCDC input filter HV AC Connector Pilot signal