Client’s Requirement: The client, a leading provider of industrial products and electronic components, was looking for a partner to help them develop a high-capacity on-board charger (OBC) for an upcoming electric vehicle (EV) model. LTTS’ (L&T Technology Services) well established automotive practice combined with its understanding of complex power electronics development, made it the natural choice for the client when it came to engineering an OBC.
Challenges: The two main challenges were:
- The charger had to be designed in such a manner that it would fit inside the given space in the EV without losing its efficiency.
- Software management and computational fluid dynamics (CFD) analysis of EV charger units.
Solution Deployed: LTTS undertook the complete design, development, and validation of the EV charger unit. The solution included:
- CFD & 3D Model Creation: Several detailed CFD analyses of 3D models were conducted to achieve the right fit with highest possible efficiency.
- Power Factor Correction (PFC) topology: Various topologies for PFC were considered to achieve the highest efficiency of the OBC.
- Thermal Analysis: Several thermal analysis tests were conducted to find the hotspots and re-arrange configuration with least thermal radiation.
- Power Electronics & EMC Testing: LTTS’ wide array of labs for power electronics & EMC testing were leveraged to adhere to international standards.
Tangible Business Benefits: LTTS’ solution provided quantifiable business benefits.
- Highest level fit achieved within the shortest time
- Final product had the charging efficiency of ~95 percent
- Zero defect product, and the customer accepted it as-is without any iterations