New series LLC set with combined transformer and resonance inductor

Premo has developed an efficient triple 3.6kW LLC (ideal for 400V Input) set with a transformer and resonance inductor specifically designed for onboard chargers capable of handling up to 11kW of power. Its compact design, durability, and high efficiency make it a popular choice among OBC manufacturers.

The BCBM-11KW-004 series is a high-reliability and high-efficiency solution developed to minimise energy losses throughout the charging process, which assists in reducing the charging system's overall energy consumption. This can be particularly important for EVs, where efficient energy use can help maximise the vehicle's range and minimise charging times.

The combined unit features a compact design, 158cm x 98cm x 38cm, and is lightweight, with only 1500g total weight and reduced volume, making it ideal for EV usage onboard chargers where space is at a premium. It is also created to be highly durable and withstand the rigours of daily use in demanding environments.

Using specific thermal conductive encapsulation material, like Coolmag, improves the performance capability of the part. During manufacturing, the encapsulation process guarantees no bubbles or voids inside the part, removing the possibility of thermal runaways or failures.

The company has developed a fully automatic manufacturing process for this part design. The current production is fully automated using Premo Robotics cobots. Due to this high automatisation level, high volume demand from electric and hybrid vehicles is secured with top-notch quality levels.

This solution provides a 14:15 Turn Ratio and a main inductance value of 115uH. It offers a switching frequency of 98-150KHz and an output voltage of 240-460V/<14.7Arms. The family comprises solutions with 4kW, 7kW, 11kW and 22kW. This set can be customised according to customer needs.

PCIM Europe 2023, 9-11 May 2023, Hall 6, Stand 232.