ENG-02 · Energy & Power
6.6 kW Bidirectional OBC and V2G Power Conversion PCBA
A representative high-voltage architecture for grid-to-battery charging and controlled battery-to-grid energy return using bidirectional power-factor correction and isolated DC conversion.
Project context
A representative engineering program
A representative high-voltage architecture for grid-to-battery charging and controlled battery-to-grid energy return using bidirectional power-factor correction and isolated DC conversion.
System architecture
How the electronics are organized
AC passes through protection, EMI filtering, and a bidirectional totem-pole PFC stage to a high-voltage DC link; an isolated dual-active-bridge stage then transfers energy to or from the traction battery under digital control.
Engineering risks to close
What must be resolved before release
- Sustain high efficiency while controlling switching loss, magnetics, and thermal density in both power directions.
- Coordinate grid current, DC-link voltage, isolation, precharge, and fault shutdown without unsafe transients.
- Control common-mode noise, conducted emissions, and gate-drive timing around fast wide-bandgap switching devices.
Validation plan
Evidence expected before production
- Map bidirectional efficiency, power factor, current THD, and regulation over voltage, load, and temperature.
- Verify reinforced isolation, dielectric withstand, precharge, discharge, interlock, and injected-fault responses.
- Run thermal-soak, grid-abnormality, load-step, short-circuit, EMC, and long-duration full-power tests.
Decision-ready evidence packet
What a comparable RFQ should define
This checklist turns the technical story into reviewable inputs and release records. It describes what buyers and manufacturers should agree—not a claim that every listed record applies to every build.
Design baseline
Released schematic or block diagram, interface table, power states, critical constraints, and revision owner.
Manufacturing release
Gerber or ODB++, stack-up, centroid data, assembly drawings, approved DFM dispositions, and panel assumptions.
Material control
Released BOM revision, manufacturer part numbers, AVL or alternate rules, no-substitute lines, MSL handling, and exception approvals.
Validation record
Test method, acceptance criteria, sample or serial identity, measured result fields, and disposition. Example scope: Map bidirectional efficiency, power factor, current THD, and regulation over voltage, load, and temperature.
Production release
First-article status plus the agreed SPI, AOI, X-ray, ICT, FCT, programming, rework, OQA, labeling, and packing records.
Project-specific fields, retention periods, sampling rules, measured limits, and customer approvals are confirmed during RFQ and protected under the applicable confidentiality agreement.
Development and production controls
Manufacturing scope represented here
- Bidirectional totem-pole PFC.
- Isolated dual-active-bridge conversion.
- High-voltage sensing and gate-drive control.
Technical image review
Board-level evidence
White-background views are published to make component placement, interfaces and assembly boundaries easier to inspect.
