As electric vehicle platforms continue to evolve, the integration of power electronics is becoming a key design decision for manufacturers. One example is the combination of an onboard charger and a DC/DC converter into a single unit. Integrated systems, such as a 2 in 1 11 kW onboard charger with a 3 kW DC/DC converter, are increasingly being evaluated as alternatives to separate modules.
Traditionally, these two components operate as independent units within the vehicle’s electrical architecture. The onboard charger converts AC grid electricity to charge the high voltage battery, while the DC/DC converter reduces high voltage battery output to supply low voltage systems such as lighting, control units and auxiliary electronics.
By integrating both functions into a single enclosure, manufacturers can simplify vehicle architecture. This approach reduces the number of housings, electrical connectors and mounting points required in the vehicle. Fewer interfaces can also simplify wiring harness design and reduce potential failure points.
Integrated systems may also provide advantages in packaging and weight reduction. With shared cooling and structural components, the overall system mass can be reduced and installation space optimized, which is particularly relevant in electric buses and commercial vehicles where space allocation is critical.
From a manufacturing perspective, combining modules can reduce the number of parts in the bill of materials and simplify assembly processes. Integrated diagnostics and software updates can also improve maintenance efficiency and support predictive service strategies for fleet operators.
However, separate modules may still be preferable in certain cases. Vehicle platforms requiring high modularity, specific thermal zoning or retrofit installations may benefit from keeping components independent.
As electrification advances across commercial vehicles and buses, the choice between integrated and separate power electronics systems increasingly depends on platform architecture, operational requirements and lifecycle cost considerations.
