Integrated 6.6kW 2-in-1 OBC Solution for European EV Pickup Manufacturer

A leading European OEM specializing in new energy utility vehicles is developing a next-generation, all-electric pickup truck for the consumer and light-commercial markets. To balance long-range capability with daily charging convenience, they required a high-performance power conversion system capable of seamless integration into a high-voltage architecture.

• High-Voltage Compatibility: Reliable support for a 345V/210Ah high-voltage LFP battery system.
• Spatial Constraints: Pickup chassis require maximized space for battery packs and cargo; the charging system must be ultra-compact.
• Thermal Management: The vehicle demands sustained high-power operation in diverse European climates, requiring superior heat dissipation.
• System Synergy: Full compatibility with the vehicle’s BMS and VCU via encrypted CAN communication for real-time diagnostics and safety.

CTS deployed an Automotive-Grade 2-in-1 Integrated Power Solution, combining a 6.6kW On-Board Charger (OBC) and a 1.5kW DC-DC Converter into a single, compact housing.

• Core Configuration: 6.6kW OBC + 1.5kW DC-DC Integrated Unit.
• Cooling System: Advanced Liquid Cooling technology to ensure optimal junction temperatures during long-term charging cycles.
• Communication: Dual-channel CAN 2.0B support for high-speed data exchange between the charger, BMS, and vehicle control unit.
• Durability: IP67-rated enclosure, resistant to water, dust, and heavy vibrations typical of pickup utility usage.

• Optimized Spatial Layout: The 2-in-1 integration reduces volume by 25-30% and eliminates extra high-voltage cabling and connectors, simplifying the vehicle assembly process.
• Superior Charging Efficiency: Delivers >95% efficiency, minimizing energy loss and shortening charging windows for the end-user.
• Automotive-Grade Reliability: Designed to IATF 16949 standards, the liquid-cooled IP67 design ensures a maintenance-free lifecycle even in harsh off-road or industrial environments.
• Smart Interaction: Intelligent charging curves and real-time monitoring enhance battery health and overall vehicle safety.