The on-board charger is an important electronic component in battery electric vehicles and plug-in hybrids. It converts alternating current (120/230 AC) from the power grid into direct current (400/800 DC) so that it can be stored in the high-voltage battery. It is essential for charging at a normal socket or wallbox, determines the maximum charging power for this type of charging and ensures a safe, efficient and regulated charging process.
The on-board chargers come directly from MAHLE's original equipment and will initially cover models from the Peugeot, Citroën, DS, and Opel brands from the Stellantis Group. MAHLE has a strong position in original equipment for drive, charging and thermal management systems. In the short to medium term, the company will expand its e-mobility product range for its customers in the international aftermarket. MAHLE will launch on-board chargers in various performance levels and with different specifications.
A defect in the on-board charger not only has a negative impact on charging performance, but also on other electronic components. High-voltage spikes can damage semiconductors or control circuits, lead to a loss of communication with the BMS or charger or cause electrical interference due to faulty filtering.
Customers notice a problem with the OBC relatively clearly: the vehicle cannot be charged with alternating current, can only be charged very slowly or the charging process is interrupted at times. The OBC may then be overheating due to internal faults, which leads to safety shutdowns. Unusual noises (clicking, buzzing) during the charging process can also indicate a faulty relay or capacitor in the OBC.
Early detection can prevent damage to the battery and ensure safe, reliable charging.