What Is a DC-to-DC Converter?

DC-DC converters are electronic devices used to convert a direct current (DC) voltage from one level to another. They are widely used in various applications, including power supplies for electronic devices, renewable energy systems, and electric vehicles. DC-DC converters come in different types, designs, and functionalities depending on their intended use.

One common type of DC-DC converter is the buck converter, which steps down the input voltage to a lower output voltage using a switch and an inductor. It is commonly used in battery charging applications, where the input voltage is higher than the battery voltage. The boost converter, on the other hand, steps up the input voltage to a higher output voltage and is used in applications where the input voltage is lower than the required output voltage, such as in LED lighting.

Another type of DC-DC converter is the flyback converter, which is commonly used in low-power applications where isolation between the input and output voltage is required. The flyback converter stores energy in an inductor when the switch is closed and transfers it to the output when the switch is open.

Design considerations for DC-DC converters include efficiency, size, cost, and reliability. Some of the challenges faced in designing DC-DC converters include high-frequency noise, electromagnetic interference, and thermal management.

In summary, DC-DC converters play a critical role in many electronic applications by converting DC voltages from one level to another. Different types of DC-DC converters exist, each with unique features and designs that make them suitable for specific applications. Designers must consider various factors when designing DC-DC converters, including efficiency, size, cost, and reliability, while also addressing the challenges associated with their design and operation.

In new energy vehicle, They are often utilized as an intermediary between systems of different voltage levels throughout the vehicle. DC-to-DC converters remain a vital part of control circuitry in all vehicles today.

As BEVs require a more robust converter due to their high level of electrical power, typical BEV batteries range from 400V to 800V. To power various electronics in the vehicle, such as air conditioning units, the voltage must be stepped down to lower levels, such as 48V or 12V. Conversely, when a battery running at 400V is connected to an 800V charging station, the voltage may need to be stepped up.

High-voltage DC-to-DC converters are heavier and larger than their low-voltage counterparts due to the extra shielding required to protect nearby components from electromagnetic interference generated by increased current. However, EV designers are turning to DC-to-DC converters with higher power density to reduce size and weight, measured in kilowatts of power per unit of volume, thereby extending the vehicle's range. For example, stepping 400V or 800V to 12V requires a DC-to-DC converter with power ranging from 700W to 4kW, and up to 12kW for commercial vehicles.

To optimize space and maintain safety and efficiency, some automakers combine the main 400V or 800V battery with a more sophisticated DC-to-DC converter instead of retaining a separate 12V battery.

LANDWORLD's expertise in electrical/electronic systems and packaging space enables them to fulfill performance, functional safety, and compute and power needs while leading the way in vehicle electrification solutions. LANDWORLD offers industry-leading DC-DC converters catalog that allow customers to differentiate their power designs. We provide a clear explanation for selecting the ideal DC-DC converter from our broad lineup.