6.1kW/L Power Density! Sungrow E-Power Launches Single-Stage On-board Charger Solution

Sungrow E-Power introduced a brand-new integrated on-board charger solution. This solution replaces the traditional PFC+DC/DC two-stage topology design with an innovative single-stage topology architecture. Combined with AI-driven parameter optimization, advanced control algorithms, and optimized thermal management, it achieves an industry-leading power density of 6.1kW/L and a full-voltage charging efficiency of 96.2%. This breakthrough opens new pathways for vehicle lightweight and overall energy efficiency improvement, offering a superior choice for the market.  

The new-generation on-board charger solution adopts a single-stage conversion circuit, enabling bidirectional AC/DC power control with just one isolation conversion, significantly simplifying system design. The power devices utilize top-side cooling, effectively reducing thermal resistance, while the power loop area is substantially minimized, further enhancing system integration. Compared to traditional solutions, the overall weight is reduced by over 25%, and the power density is increased by 65%, reaching 6.1kW/L. This makes it easier to integrate with vehicle electrical systems and supports lightweight vehicle design.  

The solution deeply integrates AI algorithms, enabling rapid parameter optimization. Based on a resonant conversion circuit, precise mathematical modeling is applied to achieve a multi-objective, multi-degree-of-freedom control strategy. This ensures soft switching of power devices across the full range, reducing losses and significantly improving system efficiency. The full-voltage range OBC achieves an average full-load efficiency of 96.2%, with a peak efficiency of up to 98.02%, helping to enhance vehicle energy efficiency and reduce end-user charging costs.  

Unlike traditional solutions, the single-stage design eliminates the bus electrolytic capacitors, which are susceptible to temperature and voltage fluctuations, through innovative circuit design and advanced control strategies. This removes the lifespan limitations of these components, significantly extending the overall service life of the OBC.  

Based on a platform design philosophy, the solution allows flexible selection of third-generation semiconductor devices such as SiC and GaN, adapting to 400V and 800V DC voltage platforms to meet diverse customer needs.  

With years of technical expertise, Sungrow E-Power remains committed to innovation and actively explores cutting-edge technologies in automotive power electronics. Building on this single-stage innovation, we will develop a diversified product platform to provide customers with more convenient, efficient, and safe on-board charger systems, driving the vigorous development of the new energy vehicle industry.