ENG-02 · Energy & Power
6.6 kW Bidirectional OBC and V2G Power Conversion PCBA
A representative 6.6 kW bidirectional on-board charger PCBA reference: grid-to-battery charging and V2G energy return with bidirectional PFC and isolated DC conversion.
Project context
How this product is typically engineered
A representative 6.6 kW bidirectional on-board charger PCBA reference: grid-to-battery charging and V2G energy return with bidirectional PFC and isolated DC conversion.
System architecture
Typical architecture
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 resolve
Decisions to close 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
Checks to define 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.
What to put in the RFQ
Files and records to agree before quoting
Use this list to agree the build inputs and release records for a similar product. The final set depends on the project.
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.
During RFQ review, we confirm the required fields, sampling, limits, approvals, and record-retention period. Confidential project information stays within the agreed access rules.
Development and production controls
Typical manufacturing scope
- 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.
