The international automotive supplier Forvia Hella is enhancing its power electronics portfolio for electric vehicles (EVs) with the introduction of its innovative High Voltage PowerBox (HV PowerBox). The HV PowerBox integrates both a high voltage converter and an onboard charger into a single product. The onboard charger serves as the interface between the EV and the power grid, while the high voltage converter transforms the 400V or 800V voltage to 12V, powering essential vehicle electronics such as safety sensors and comfort functions. This technology is slated to go into series production in 2027.
By combining the onboard charger and high voltage converter, the HV PowerBox achieves an exceptionally high power density, delivering over 3 kW per liter of its volume. This compact design offers more power in a smaller housing, while also achieving an overall efficiency of 97%. This high efficiency means fewer energy losses during charging, leading to reduced electricity costs for EV owners.
The integration of both components not only optimises power delivery but also results in cost savings for materials, logistics, and development, simplifying vehicle integration. The HV PowerBox features a new housing technology, an innovative heating and cooling system, and an intelligent design aimed at cost-efficient mass production. This approach reduces the overall weight of the system by 20 to 25%. Additionally, the HV PowerBox can integrate other essential e-mobility components such as a high-voltage battery management system, secondary voltage converter, e-fuses, or an intelligent Power Distribution Module (iPDM).
Jörg Weisgerber, Managing Director Electronics at Forvia Hella, said, 'For e-mobility to become more widely embraced, it is crucial that EVs can be charged quickly, safely, and efficiently, in addition to offering a good range. We produce around three million 48V/12V voltage converters annually, and next year, we will launch our first high voltage converter in series production. With the HV PowerBox, we are building on our extensive expertise and expanding our portfolio with another key component for electromobility and autonomous driving.'
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