On-Board Charger & DC/DC Converter System

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Compact and lightweight design
For worldwide usage with a wide input range, 1 phase and 3 phase
Bidirectional power flow (V2X) versions available
High-voltage versions available
Scalable platform for various products

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SKU BGEN-ON-BOARD-CHARGER-AND-DC-DC-CONVERTER-SYSTEM Category Auxiliary System Tags Bus & Coach, Heavy Truck & Tractor, Light Commercial Vehicle

Description

Combined onboard charger and DC/DC converter module

This system integrates the functionality of an onboard charger and a DC/DC converter into a single unit. Both the onboard charger and DC/DC converter provide real-time data on voltage, current, and other parameters via the CAN bus, facilitating communication and status feedback with the BMS and VCU.

High Power Density

Employs advanced high-frequency digital control technology, achieving high power density and facilitating seamless integration into the vehicle's overall system.
Versatile Configuration

Offers multiple low-voltage signal ports and a wide voltage output range. Customizable and adjustable charging strategies are available to suit the requirements of various vehicle systems.
Excellent Heat Dissipation

The housing is precision die-cast as a single unit and incorporates a 3D water channel design for efficient heat dissipation.
Enhanced Safety

Features comprehensive protection mechanisms during charging, including input/output overvoltage and undervoltage protection, short circuit protection, over-temperature protection, etc., ensuring reliable and safe operation.

Our offerings

Please be aware that the input and output voltage ranges provided below represent the general range for this power category. For specific product details, kindly reach out to us.

On-board Charger		DC/DC Converter			PDU	Cooling method
Power	Output voltage range	Power	Input voltage range	Output voltage	PDU	Cooling method
3.3 kW	50 - 450 VDC	1 kW	40 - 545 VDC	14 V	No	Air cooling
3.3 kW	95 - 450 VDC	1.5 kW	88 - 454 VDC	14 V	No	Liquid cooling
6.6 kW	95 - 450 VDC	1.5 kW	88 - 454 VDC	14 V	No	Air cooling / liquid cooling
6.6 kW	200 - 450 VDC	2 kW	206 - 454 VDC	14 V	No	Air cooling / liquid cooling
6.6 kW	250 - 460 VDC	2 kW	300 - 460 VDC	14 V	Yes	Liquid cooling
6.6 kW	270 - 450 VDC	2 kW	270 - 450 VDC	14 V	No	Liquid cooling
6.6 kW	200 - 420 VDC	2.5 kW	200 - 450 VDC	14 V	Yes	Liquid cooling
6.6 kW	360 - 785 VDC	3 kW	360 - 785 VDC	14 V	No	Liquid cooling
6.6 kW @1φ 9.9 kW @3φ	350 - 800 VDC	3 kW	350 - 800 VDC	14 V	No	Liquid cooling
6.6 kW @1φ 9.9 kW @3φ	200 - 450 VDC	2.5 kW	200 - 450 VDC	14 V	No	Liquid cooling
6.6 kW @1φ 9.9 kW @3φ	230 - 500 VDC	2.5 kW	230 - 500 VDC	14 V	Yes	Liquid cooling

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Requirements Analysis

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Solution Design

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Deliver worldwide with integration support and technical assistance

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Our Solutions

Proven Electrification Solutions Delivered Worldwide

Our Projects

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FAQs

What does Brogen supply for electric commercial vehicles?

Brogen supplies electrification components and systems across six families: EV charging (Level 2 AC, Level 3 DC and charger power modules), on-board power electronics (on-board charger, DC/DC converter, combined OBC + DC/DC system and integrated auxiliary inverter), electric steering (EHPS, EPS and RCB steering gear), electric braking (air brake compressor, vacuum pump), battery thermal management, and electric air conditioning. Every product is engineered for integration into a vehicle programme rather than as a stand-alone accessory.

Which vehicles are your products designed for?

Our components are used across commercial and specialty vehicles — bus and coach (including mini and mid-sized buses), heavy truck and tractor units, light commercial vehicles and light trucks, specialty and municipal vehicles such as construction machinery, sanitation vehicles and mining trucks, and for selected lines passenger cars and SUVs. If you tell us the vehicle type and platform, we will point you to the right product family.

Are your products compatible with both electric and conventional vehicles?

Yes. Steering systems are explicitly designed to be fitted to both fuel vehicles and new energy vehicles, and the on-board power electronics and charger range covers PHEV and BEV applications — with the electric vacuum pump supporting HEV, BEV and FCV as well. This makes the range suitable for electrification programmes that run alongside existing combustion platforms.

Can you customise a solution for our specific vehicle programme?

Yes. The range is built on platform and platforming designs rather than one-off parts, so a base platform can be scaled and configured to different vehicle types, power levels and voltage architectures. Customisable and adjustable control strategies are available, and tailored OEM solutions are offered for commercial vehicle applications.

How do your products integrate with the vehicle's control and communication systems?

Communication is native to the products rather than an add-on. Depending on the product, interfaces include CAN and CAN-FD and K-line protocols, and the combined on-board charger and DC/DC system provides real-time voltage and current data over the CAN bus for communication and status feedback with the BMS and VCU. Selected products also support online software upgrades and OTA updates, so control strategy can be refined after the vehicle is in service.

What protection and reliability features do your products include?

Protection is designed in at component level. Depending on the product this includes input and output overvoltage and undervoltage protection, short circuit protection, over-temperature protection, overcurrent protection, stalling protection, reverse-polarity protection and dry-running protection. Housings and sealing are engineered for demanding environments — dust and water ingress protection up to IP67 on applicable products, and operation designed to remain stable under extreme temperatures and high humidity.

How do your products help lower energy consumption and operating costs?

Several design choices work in the same direction. Power is drawn only when it is actually needed — for example the electric steering pump runs only when steering assistance is required, which improves fuel economy. High-efficiency conversion reduces energy losses, lightweight and integrated designs cut vehicle weight (the all-DC variable-frequency air conditioning system reduces overall system weight by more than 30%), and intelligent thermal management extends battery life and range.

Can the same product platform serve different markets and power configurations?

Yes. The range covers single-phase and three-phase input, 400 V and 800 V architectures, and different power and voltage configurations for global markets, with wide input ranges for worldwide usage. Because products share platform architectures, a design validated for one market can be adapted for another instead of starting from scratch.

How do we obtain the exact specification for our application?

The specifications published on this page describe the general range for this product category. To confirm the exact model — including power level, voltage window, cooling method, mounting and interface — send us your vehicle parameters (battery voltage architecture, power requirement and installation constraints) and we will specify the configuration that matches. A product manual is available for download on each product page for preliminary engineering review.

Why choose Brogen as an electrification partner?

Three reasons. First, breadth — charging, on-board power electronics, steering, braking, thermal management and air conditioning can be sourced from one partner, which reduces supplier complexity and interface risk. Second, platform thinking — the designs are modular and scalable, so they adapt to a wide range of vehicle types and configurations. Third, engineering responsiveness — advanced control concepts and intelligent algorithms give broad vehicle model compatibility, enabling fast matching and rapid development cycles.

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