Table of Contents

• Power Converter Applications
• Common Solution Requirements
• The RECOM Approach
• Featured RMOD Products
• Summary

DC/DC Converter Applications for E-Mobility

Electric and hybrid power for industrial mobility systems has reached a level of efficiency that makes it a standard option driven by everyday economic factors. It is no longer considered exotic or unconventional as a power source for heavy equipment. RECOM offers the RMOD line of rugged DC/DC power converter solutions, ideally suited for heavy-duty applications.

Hybrid and pure electric propulsion require multiple power conversion steps to accommodate various DC power requirements. Mains 3-phase AC power at 400 volts is converted to DC to charge the main traction battery pack, which can range from 24 volts to 920 volts. Traction battery power must be converted to usable levels with a DC/DC power converter, such as the RECOM RMOD, to supply on-board low-voltage electronic systems.

RECOM’s RMOD DC/DC converters translate and isolate DC from the traction battery pack to the lower voltage required by on-board back-end electronics. This back-end DC is used to keep a low-voltage backup battery charged and to power sensors, GPS, communications, lighting, on-board intelligence, and other essential systems.

Requirements for Rugged DC/DC Converters

On- and off-road vehicles in the materials handling, construction, and transportation industries require a rugged design, reliable regulation over a wide input voltage range, galvanic isolation, and strong noise immunity. Traction batteries are subject to voltage sag under high load or when approaching a discharged state. The DC/DC converters must maintain a steady output voltage and power regardless of the burden on the traction supply.

Mobile power supplies and power converters require broad input voltage compatibility and a wide range of power capacities. They also have requirements specific to their end-use environment. When mounted on vehicles and other mobile platforms, power units are exposed to dust, water, grease, fumes, and other contaminants. They must operate reliably under excessive heat or cold as well as vibration and shock.

The RECOM Approach: Versatile Power for E-Mobility

Regardless of the application, RECOM RMOD DC/DC converters form the foundation of a low-voltage bus for industrial e-mobility systems.

Delivering a Wide Selection in V_IN and V_OUT

Electric vehicles use a broad range of traction motor voltages. Carts and utility vehicles can operate with traction battery voltages as low as 24V or even 12V. At the high end, heavy equipment, large passenger movers, and other high-power systems use traction motor voltages up to 800V. RMOD models start with a 12V minimum input voltage and extend up to 950V.

The 18kW – 22kW RMOC22009 AC/DC on-board charger adds to the product line with 400V, three-phase AC input and 450VDC to 920VDC output for charging large high-voltage traction batteries in shunting locomotives and other high-horsepower heavy equipment.

Rugged, Reliable Design

RMODs are built to be installed in equipment that may spend its operating life exposed to the elements and harsh environmental conditions. RMODs feature dust and water immersion protection rated to IP67. The 6 indicates solids, the highest dust protection rating. The 7 indicates watertightness to 1 meter for up to 30 minutes. This is sufficient for outdoor use and low-pressure spray-wash cleaning. The units are not certified for high-pressure water or steam cleaning.

Application Flexibility

• Some RMODs are designed for parallel operation, allowing multiple units to run in parallel to increase power capability or redundancy.
• Most RMOD connectors are compatible with industry standards for easier interoperability.
• Most models use baseplate cooling for simplicity, while higher power units may also offer water cooling.
• All models are designed to meet applicable industry electromagnetic compatibility EMC standards.
• RMODs support 100% duty cycle for continuous 24/7 operation.

RMOD DC/DC Power Converters

The RMOD line of DC/DC power converters features input voltages from 12V to 950V. Power capacity ranges from 300W to 4200W with the high-power RMOD4000-EW. This voltage and power range covers vehicles from small forklifts or utility tractors up to large transit systems with extensive low-voltage bus requirements.

Summary

RECOM RMOD DC/DC converters convert on-board traction battery voltage to low-voltage bus-level power. Applications include on- and off-road electric and hybrid vehicles used in materials handling and heavy equipment. Several models also support vehicles such as trains or aircraft that require low voltage at 2kW or higher power levels. As more hydraulic systems are converted to electric power and more microcontrollers, communication units, and smart control electronics are added, greater demands are placed on the low-voltage supply. The RECOM RMOD can be an integral part of these systems by providing reliable back-end power.