Vicor Introduces Advanced Automotive-Grade Power Modules for 48V EV Systems

Vicor has unveiled three new automotive-grade power modules designed to meet the growing demands of 48V electric vehicle (EV) systems. These modules—BCM6135, DCM3735, and PRM3735—boast industry-leading power density and are built to support automotive manufacturers and Tier 1 suppliers by 2025. Developed with AEC-Q100 certified integrated circuits (ICs) designed by Vicor, these power modules have also passed the rigorous PPAP (Production Part Approval Process) testing with automotive customers.

“Vicor is setting new benchmarks in automotive power density,” said Patrick Wadden, Vice President of Vicor’s Automotive Business Unit. “Our scalable and compact power modules provide automotive manufacturers with innovative solutions to reduce the size and weight of power systems across vehicles.”

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Overview of the New Power Modules

1. BCM6135 – 2.5kW BCM® Bus Converter:
   • Efficiency: 98%
   • Function: Converts 800V traction battery output to 48V SELV (Safety Extra-Low Voltage).
   • Power Density: 158kW/L
   • Key Feature: Acts as a virtual 48V battery, replacing traditional 48V batteries to cut costs and reduce vehicle weight by up to 25kg.
   • Application: Offers isolation between high- and low-voltage systems, reducing the space required for DC-DC conversion. With a rapid transient response of 8 mega amps per second, it efficiently handles bidirectional power flow, improving energy management.
2. DCM3735 – 2.0kW DCM™ DC-DC Converter:
   • Function: Converts 48V to a regulated 12V supply for vehicle sub-systems.
   • Power Density: 300kW/L
   • Compatibility: Supports a range of applications by offering an adjustable output from 8V to 16V.
   • Use Case: Optimizes zonal electrical control unit (ECU) applications by bridging 48V and 12V systems.
3. PRM3735 – 2.5kW PRM™ Regulator:
   • Efficiency: 99.2%
   • Power Density: 260kW/L
   • Application: Provides high-efficiency regulation for 48V systems in next-generation vehicle architectures. Its compact design saves space, helping reduce both the volume and weight of power systems.

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Applications and Advantages

These new modules offer more than 300 configuration options, allowing automotive designers to tailor power systems for a variety of needs. As the automotive industry shifts towards 48V zonal architectures, these modules enable seamless conversion between 800V, 400V, 48V, and 12V systems, ensuring improved efficiency and reduced complexity.

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Key Use Cases

1. Active Suspension Systems:
   Traditional 12V systems can’t meet the power demands of advanced suspension systems. By leveraging the BCM6135, EV manufacturers can use a 48V bus for active suspension. With its rapid current reversal capability, the module also manages regenerative power by sending it back to the main battery.
2. Eliminating the 48V Battery:
   The BCM6135 can serve as a virtual 48V battery, removing the need for a physical 48V battery in EVs. Its ability to switch from zero to full current at 8 mega amps per second enables it to instantly step down the 800V traction battery to 48V, reducing vehicle weight and costs. This feature alone can save manufacturers up to $100 per vehicle.
3. Facilitating 48V Zonal Architectures:
   The transition to 48V zonal architecture is a priority for automotive manufacturers, and Vicor’s power modules are critical in this evolution. The DCM3735 works alongside the BCM6135 to provide a stable 12V supply from the 48V bus. Designers can position the DCM3735 remotely within vehicle zones (e.g., the right-hand side) to deliver local 12V power, achieving up to 90% of the cost and weight savings associated with the 48V transition.
4. Precharging to Prevent Current Surges:
   Precharging is essential to prevent damaging current surges during start-up. The traditional approach uses contactors and resistors, adding 1kg in weight and over $50 in costs. Vicor’s BCM6135 and PRM3735 provide a more efficient alternative. These modules can boost the low-voltage battery’s power to high voltage, eliminating the need for legacy contactors and resistors.

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Versatility and Performance for a Wide Range of Applications

The flexibility of Vicor’s power modules opens new possibilities for EV manufacturers. These modules not only simplify power conversion from the main 800V or 400V traction battery to 48V but also efficiently support 12V legacy systems within new vehicle architectures. Whether used to deliver point-of-load power or to manage power sharing across multiple systems, Vicor’s solutions offer exceptional power density, reduced losses, and simplified designs.

“Our modules are making it easier for manufacturers to transition from legacy 12V systems to modern 48V architectures,” added Wadden. “They offer unparalleled efficiency and allow our customers to reduce the size and weight of power systems, enhancing overall vehicle performance.”

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Learn More

To explore Vicor’s new automotive-grade power modules and their full range of configurations, visit the official website or contact Vicor for further information.