{"id":14357,"date":"2026-07-03T09:00:00","date_gmt":"2026-07-03T07:00:00","guid":{"rendered":"https:\/\/tps-elektronik.com\/?p=14357"},"modified":"2026-06-05T08:08:16","modified_gmt":"2026-06-05T06:08:16","slug":"what-is-tps-automotive-power-module-for-on-board-chargers-and-why-it-is-essential-for-fast-and-efficient-ev-battery-charging","status":"publish","type":"post","link":"https:\/\/tps-elektronik.com\/en\/what-is-tps-automotive-power-module-for-on-board-chargers-and-why-it-is-essential-for-fast-and-efficient-ev-battery-charging\/","title":{"rendered":"What Is TPS Automotive Power Module for On\u2011Board Chargers and Why It Is Essential for Fast and Efficient EV Battery Charging?"},"content":{"rendered":"<article class=\"product-blog\" lang=\"en\"><header>\n<p>For system integrators and procurement teams in the electric vehicle supply chain, the on\u2011board charger (OBC) is no longer a simple AC\u2011to\u2011DC converter. It is a bidirectional energy gateway that must deliver high efficiency. Which meet stringent automotive safety standards, and operate reliably across extreme temperature and vibration conditions. When a Tier\u20111 supplier selects the power stage for a next\u2011generation 6.6\u202fkW OBC, the decision hinges on a single component: the <strong>automotive power module<\/strong>.<\/p>\n<p>The <a href=\"https:\/\/www.shop-tps.com\/shop\/category\/power-modules-179\" target=\"_blank\" rel=\"noopener noreferrer nofollow\"><strong>TPS Automotive Power Module<\/strong><\/a>, based on the TPS\u2011BM142400SI platform. Which engineered precisely for this application. It combines an active power factor correction (PFC) front end, a high\u2011efficiency isolated DC\u2011DC converter. And advanced digital control into a compact, thermally optimized package. With support for bidirectional operation, the module not only charges the high\u2011voltage battery from the grid but also enables vehicle\u2011to\u2011grid (V2G) and vehicle\u2011to\u2011load (V2L) functionality. Which making it a future\u2011proof choice for modern EV platforms.<\/p>\n<\/header><nav class=\"toc\" aria-label=\"Table of Contents\">\n<h2 id=\"toc-en\">Table of Contents<\/h2>\n<ol>\n<li><a href=\"#en-why-obc\">Why the on\u2011board charger power module defines EV charging performance<\/a><\/li>\n<li><a href=\"#en-platform\">TPS\u2011BM142400SI: the bidirectional automotive power module platform<\/a><\/li>\n<li><a href=\"#en-electrical\">Electrical performance: efficiency, PFC, and power quality<\/a><\/li>\n<li><a href=\"#en-thermal\">Thermal design and reliability for automotive environments<\/a><\/li>\n<li><a href=\"#en-scalability\">Scalability: parallel operation for higher power OBCs<\/a><\/li>\n<li><a href=\"#en-compliance\">Automotive compliance: IEC\u202f61851, ISO\u202f16750, and EMC<\/a><\/li>\n<li><a href=\"#en-applications\">Application scenarios: OBC, V2G, and test systems<\/a><\/li>\n<li><a href=\"#en-rfq\">RFQ checklist for automotive power modules<\/a><\/li>\n<li><a href=\"#en-faq\">Frequently Asked Questions<\/a><\/li>\n<\/ol>\n<\/nav>\n<section>\n<h2 id=\"en-why-obc\">Why the on\u2011board charger power module defines EV charging performance<\/h2>\n<p>An on\u2011board charger converts AC mains power into regulated DC voltage to charge the traction battery. In a typical 6.6\u202fkW OBC, the power module must deliver 14\u202fV to 16\u202fV DC at over 400\u202fA to the battery pack. While drawing a nearly sinusoidal current from the grid with a power factor above 0.99. This demands a power stage that combines a totem\u2011pole PFC rectifier and a resonant DC\u2011DC converter. All controlled by a high\u2011speed digital signal processor.<\/p>\n<p>The efficiency of this power module directly affects the vehicle\u2019s range and charging speed. A 1\u202f% efficiency improvement at 6.6\u202fkW saves 66\u202fW of dissipation. Which reduces the burden on the vehicle\u2019s thermal management system and extends the driving range. The TPS\u2011BM142400SI achieves up to 91.5\u202f% AC\u2011DC efficiency, with a SiC\u2011based variant capable of exceeding 94\u202f%. This high efficiency maintained across the wide input voltage range of 176\u2013264\u202fV AC, adapting to single\u2011phase grids worldwide. For further technical background on power conversion in demanding environments, see the <a href=\"https:\/\/tps-elektronik.com\/en\/services\/\">TPS services overview<\/a>.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-14403\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/Automotive-OBC-Power-Module-Bidirectional-AC\u2011DC-SiC-Converter-EV-Charger-\u2013-TPS-Elektronik-1.jpg\" alt=\"Automotive OBC Power Module Bidirectional AC\u2011DC SiC Converter EV Charger \u2013 TPS Elektronik Automotive OBC Power Module Bidirektionaler AC\u2011DC SiC\u2011Wandler EV\u2011Ladeger\u00e4t \u2013 TPS Elektronik\" width=\"1920\" height=\"1078\" \/><\/p>\n<\/section>\n<section>\n<h2 id=\"en-platform\">TPS\u2011BM142400SI: the bidirectional automotive power module platform<\/h2>\n<p>The TPS\u2011BM142400SI is a 2400\u202fW bidirectional power module that can configured as a single\u2011phase OBC power stage for 3.3\u202fkW applications. Or two modules can be interleaved for a 6.6\u202fkW OBC. The module incorporates advanced soft\u2011switching technology (zero\u2011voltage switching on the primary side and zero\u2011current switching on the secondary side) to minimize switching losses and electromagnetic interference.<\/p>\n<p>Key hardware features include a 176\u2013264\u202fV AC input with \u226415\u202fA AC current, a 14\u202fV DC output at 171\u202fA (or 15\u202fV DC input at 112\u202fA for reverse operation). And a fast mode\u2011switching time of less than 10\u202fms between rectifier and inverter modes. This rapid transition is essential for V2G applications, where the OBC must seamlessly switch from charging to discharging when the grid demands power. The module\u2019s power density and control flexibility are described in more detail in the <a href=\"https:\/\/tps-elektronik.com\/en\/news-insights\/\">TPS news and insights<\/a> technical archive.<\/p>\n<\/section>\n<section>\n<h2 id=\"en-electrical\">Electrical performance: efficiency, PFC, and power quality<\/h2>\n<p>Power quality is a critical metric for any grid\u2011connected charger. The TPS\u2011BM142400SI achieves a power factor greater than 0.99 and total harmonic distortion of input current (THDi) below 5\u202f% at 220\u202fV AC full load, assuming grid voltage THD \u22642\u202f%. These figures exceed the requirements of IEC\u202f61000\u20113\u20112 Class\u202fA for harmonic emissions, which ensuring that the OBC will not cause excessive harmonic distortion on the local grid.<\/p>\n<p>On the DC side, the module provides an output voltage accuracy of \u00b10.5\u202f% and a ripple voltage of 500\u202fmV peak\u2011to\u2011peak. Which ensuring stable charging current to the battery management system. The digital control loop employs a combination of average current\u2011mode control for PFC and peak current\u2011mode control for the DC\u2011DC stage, with adaptive dead\u2011time adjustment to maximize efficiency across the load range. The module\u2019s performance parameters and typical application circuits further explored in the <a href=\"https:\/\/www.shop-tps.com\/shop\/category\/power-modules-179\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">TPS power modules product category<\/a>.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-14393\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/Automotive-Power-Module-Liquid-Cooling-Forced-Air-Thermal-Management-Heat-Sink-\u2013-TPS-Elektronik-3.jpg\" alt=\"Automotive Power Module Liquid Cooling Forced Air Thermal Management Heat Sink \u2013 TPS Elektronik Automotive Power Module Fl\u00fcssigkeitsk\u00fchlung Zwangsbel\u00fcftung Thermomanagement K\u00fchlk\u00f6rper \u2013 TPS Elektronik\" width=\"1920\" height=\"1078\" \/><\/p>\n<\/section>\n<section>\n<h2 id=\"en-thermal\">Thermal design and reliability for automotive environments<\/h2>\n<p>Automotive electronics must operate reliably from \u221240\u202f\u00b0C cold\u2011start conditions to +85\u202f\u00b0C ambient under the hood. The TPS\u2011BM142400SI rated for full\u2011load operation from 10\u202f\u00b0C to 45\u202f\u00b0C, with linear derating to 80\u202f% load at 55\u202f\u00b0C\u201360\u202f\u00b0C. The module uses an intelligent forced\u2011air cooling system (front inlet, rear outlet default) with a variable\u2011speed fan controlled by internal temperature sensors.<\/p>\n<p>For integration into sealed OBC enclosures, the module\u2019s baseplate designed to couple thermally to a liquid\u2011cooled cold plate, enabling silent, fanless operation. The mechanical design also addresses automotive vibration and shock requirements per ISO\u202f16750\u20113, with all power semiconductors soldered directly to the PCB or sintered to a DBC substrate for maximum thermal cycling reliability. The internal fault protection includes over\u2011temperature shutdown, input under\u2011voltage lockout, output over\u2011voltage protection, and cycle\u2011by\u2011cycle over\u2011current limiting.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-14408\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/0703-TBM14-2400SI.png\" alt=\"TBM14-2400SI automotive power module\" width=\"1024\" height=\"401\" \/><\/p>\n<\/section>\n<section>\n<h2 id=\"en-scalability\">Scalability: parallel operation for higher power OBCs<\/h2>\n<p>As EV battery capacities increase, so does the demand for higher charging power. The TPS\u2011BM142400SI supports up to eight modules in parallel with a current\u2011sharing imbalance of less than 5\u202f%. Which enabling scalable power from 2.4\u202fkW to 19.2\u202fkW in a single OBC enclosure. This scalability allows Tier\u20111 suppliers to design a single OBC platform that can be configured for different vehicle classes. From compact cars with 3.3\u202fkW chargers to luxury SUVs with 11\u202fkW three\u2011phase chargers \u2014 simply by changing the number of modules and the input phase configuration.<\/p>\n<p>The parallel control strategy uses a digital communication bus that synchronizes the switching frequencies of all modules and adjusts the output current of each module to achieve balanced load sharing. Droop control is implemented as a backup in case of communication failure. Which ensuring graceful degradation rather than a complete system shutdown.<\/p>\n<\/section>\n<section>\n<h2 id=\"en-compliance\">Automotive compliance: IEC\u202f61851, ISO\u202f16750, and EMC<\/h2>\n<p>Any power module used in an on\u2011board charger must comply with a suite of international standards. The TPS\u2011BM142400SI designed to meet the requirements of <a href=\"https:\/\/webstore.iec.ch\/en\/publication\/26747\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">IEC\u202f61851\u201123<\/a> (DC electric vehicle charging station). Which governs the electrical safety and performance of conductive charging systems. For environmental durability, the module\u2019s design references <a href=\"https:\/\/webstore.iec.ch\/en\/publication\/28396\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">ISO\u202f16750\u20112<\/a> (environmental conditions) and ISO\u202f16750\u20113 (mechanical loads).<\/p>\n<p>EMC compliance is critical, because an OBC is both a source and a victim of electromagnetic interference. The module meets EN\u202f55032 Class\u202fB (CISPR\u202f32) for radiated and conducted emissions. And it designed to pass the immunity tests of IEC\u202f61000\u20114\u20112 (ESD), IEC\u202f61000\u20114\u20113 (radiated RF), and IEC\u202f61000\u20114\u20114 (electrical fast transients). The module is eligible for UL\/CE\/TUV certification, simplifying the OBC supplier\u2019s own certification process.<\/p>\n<\/section>\n<section>\n<h2 id=\"en-applications\">Application scenarios: OBC, V2G, and test systems<\/h2>\n<p>While the primary application of the TPS\u2011BM142400SI is the on\u2011board charger, its bidirectional capability makes it suitable for several other automotive\u2011related applications:<\/p>\n<ul>\n<li><strong>Vehicle\u2011to\u2011Grid (V2G) and Vehicle\u2011to\u2011Load (V2L)<\/strong>: The module can discharge the traction battery back to the grid or to a local load. Which enabling grid stabilization services and emergency backup power.<\/li>\n<li><strong>Cell formation and battery testing<\/strong>: In manufacturing, the module can used as a bidirectional power supply for charging and discharging battery cells during formation, with energy recovered from the discharging process and returned to the grid. Which achieving up to 88.5\u202f% DC\u2011AC efficiency in reverse mode.<\/li>\n<li><strong>Power bidirectional aging tests<\/strong>: For reliability testing, the module can configured in a back\u2011to\u2011back arrangement where one module charges a battery and another discharges it. Which recycling energy and dramatically reducing the electricity cost of long\u2011duration tests.<\/li>\n<\/ul>\n<p>For all of these applications, the module\u2019s fast mode switching (&lt;10\u202fms) and high\u2011accuracy output voltage (\u00b10.5\u202f%) are critical enablers.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-14388\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/TPS-Power-Module-Parallel-Configuration-8-Modules-EV-Fast-Charging-Scalability-\u2013-TPS-Elektronik-4.jpg\" alt=\"TPS Power Module Parallel Configuration 8 Modules EV Fast Charging Scalability \u2013 TPS Elektronik TPS Power Module Parallelkonfiguration 8 Module EV\u2011Schnellladen Skalierbarkeit \u2013 TPS Elektronik\" width=\"1920\" height=\"1078\" \/><\/p>\n<\/section>\n<section>\n<h2 id=\"en-rfq\">RFQ checklist for automotive power modules<\/h2>\n<ul>\n<li><strong>OBC power level<\/strong>: 3.3\u202fkW, 6.6\u202fkW, or other; single\u2011phase or three\u2011phase input.<\/li>\n<li><strong>Bidirectional requirement<\/strong>: Is V2G\/V2L functionality required?<\/li>\n<li><strong>Cooling method<\/strong>: Liquid\u2011cooled baseplate, forced air, or a combination.<\/li>\n<li><strong>Automotive certifications<\/strong>: Target standards (IEC\u202f61851, ISO\u202f16750), required AEC\u2011Q qualification level.<\/li>\n<li><strong>Communication interface<\/strong>: CAN bus, LIN, or other for system integration.<\/li>\n<li><strong>Volume and schedule<\/strong>: Prototype quantity, series production ramp, and annual forecast.<\/li>\n<\/ul>\n<p><a href=\"https:\/\/www.shop-tps.com\/shop\/category\/power-modules-179\" target=\"_blank\" rel=\"noopener noreferrer nofollow\"><strong>Browse TPS automotive power modules and request a quote \u2192<\/strong><\/a><\/p>\n<\/section>\n<section>\n<h2 id=\"en-faq\">Frequently Asked Questions<\/h2>\n<p><strong>Can the TPS\u2011BM142400SI be used directly in a 6.6\u202fkW OBC?<\/strong><br \/>Yes, by interleaving two modules, each operating at 3.3\u202fkW, a 6.6\u202fkW OBC power stage can be built. The modules share a common DC output bus and are synchronized via the digital communication interface.<\/p>\n<p><strong>Does the module include the control software for OBC operation?<\/strong><br \/>TPS provides the hardware platform and reference control firmware. The customer can adapt the firmware to their specific BMS communication protocol and charging profile requirements.<\/p>\n<p><strong>What is the expected lifetime of the module in an automotive application?<\/strong><br \/>With proper thermal management (keeping baseplate temperature below 85\u202f\u00b0C), the module designed for a service life of 15\u202fyears or 300,000\u202fkm, consistent with automotive reliability targets. Detailed lifetime calculations can provided based on the customer\u2019s specific mission profile.<\/p>\n<p><strong>Where can I find detailed technical documentation?<\/strong><br \/>Visit the <a href=\"https:\/\/www.shop-tps.com\/shop\/category\/power-modules-179\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">TPS power modules product page<\/a> or contact TPS sales through the <a href=\"https:\/\/tps-elektronik.com\/en\/services\/\">TPS services<\/a> page to request a full datasheet and application note.<\/p>\n<\/section>\n<footer style=\"background: #2d5797; padding: 30px; border-radius: 14px; margin-top: 40px;\">\n<p style=\"color: #ffffff; font-size: 16px; line-height: 1.6; margin: 0;\"><strong>Next step:<\/strong> Power your next\u2011generation OBC with a proven, bidirectional automotive power module. <a style=\"color: #ffffff; font-weight: 600; text-decoration: underline; display: block; margin-top: 10px;\" 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It is a bidirectional energy gateway that must deliver high efficiency. Which meet stringent automotive safety standards, and operate reliably across extreme temperature and vibration conditions. 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