High voltage power electronics system for automotive

Revolutionary approach eliminates need for auxiliary low voltage (LV) batteries, lowering vehicle weight and total cost of ownership

LV batteries power an array of essential vehicle accessories and electronics in traditional and electric vehicles, including lights, infotainment systems, safety systems such as steering and braking, domain and zonal controllers, advanced driver assistance systems (ADAS), and more. When reliable operation across the electrical architecture requires more power than a single LV battery can deliver, or safety-critical components require a backup, automakers incorporate auxiliary batteries. But that performance comes with a tradeoff: additional cost and weight.

To eliminate the need for additional LV batteries, Flex improved the performance and functionality of main and backup DC/DC converters to enable an intelligent high voltage (HV) power electronics solution, a strong improvement in automotive power management.

A first-of-its-kind solution that decreases the need for auxiliary LV batteries

Flex backup DC/DC converters connect HV and LV power architectures, taking over the functionality of auxiliary LV batteries and working alongside a main DC/ DC converter. Engineered to meet key safety and performance requirements, the converters have been tested for power flow and functionality in critical use cases. They are proven to efficiently and rapidly convert voltages while ensuring key safety backups remain ready for use.

Main DC/DC Converter

Ultra-fast and bidirectional, the main DC/DC converter connects the HV propulsion system to the primary LV system.

备用 DC/DC 转换器

Small, light, and cost-effective, the backup DC/DC converter covers safety-critical events by providing near-instantaneous power to a backup LV system.

Real-world benefits, not edge-case scenarios

With proven performance in demanding, real-world scenarios, the HV power electronics solution from Flex stands to transform automotive architectures.

Heavy steering and braking

The main DC/DC converter’s ultra-fast bidirectional conversion ensures vehicle performance in situations with highly dynamic system and component loads.

ASIL D
system failure

The backup DC/DC converter takes over in under 100 milliseconds in the case of ADAS or safety system failures, supporting critical functions until vehicle safe state.

System
initialization

The main and backup DC/DC converters work in tandem to pre-charge and initialize HV systems and LV systems.

Over-the-air (OTA) updates

The backup DC/DC converter efficiently powers LV systems during vehicle sleep mode as needed. Power is supplied directly from HV battery cells to avoid turning on safety monitoring functions.

Improve affordability in hybrid and electric vehicles

With affordability a key driver of hybrid and electric vehicle adoption, eliminating the need for auxiliary LV batteries reduces the overall cost of the electrical system even as highly connected, feature-rich models are introduced to the market. The Flex HV power electronics solution gives automakers a low-maintenance path toward high-impact features and performance.

Flex 的优势

The Flex HV power electronics solution offers a robust, scalable, and production-ready solution that empowers automakers to incorporate cost-effective automotive electrical architectures with confidence.

创新 — First-to-market DC/DC converters replace the need for auxiliary LV batteries
Performance — Ultra-fast, bidirectional conversion with high power density and ASIL D ready
影响 — Significant cost and weight savings at the vehicle and system levels

Orange manufacturing arms working on a production line

Key benefits of leveraging Flex’s high voltage power electronics system:

Eliminates need for auxiliary LV batteries
Ultra-fast and bidirectional operation
High power density and ASIL D ready
Dual active bridge architecture
Significant cost and weight reduction
Validated at the component level across use cases

Accelerate next-generation safety and reliability with the Flex HV power electronics solution

Flex Automotive

Backup DC/DC Converter white paper

汽车用高压电力电子系统