Shanghai Wenlida Power Electronics Co., Ltd. —— Expert in Custom High-power Bidirectional DC/DC Converters

Shanghai Wenlida Power Electronics Co., Ltd. —— Expert in Custom High-power Bidirectional DC/DC Converters

Since its establishment in March 2005, Shanghai Wenlida Power Electronics Co., Ltd. has been deeply engaged in the field of power electronics. Relying on the strong resources of Shanghai Wenlida Co., Ltd., it has developed into a national high-tech enterprise with the new energy vehicle industry as its core business. The company has passed the automotive-grade TS16949 system certification standard and owns a specialized factory. It has been committed to providing global customers with high-efficiency, high-power-density, intelligent, and highly reliable power electronics solutions.

Full Voltage Range Customization from 60V to 2400V

In the research, development, and manufacturing of high-power bidirectional DC/DC converters, Shanghai Wenlida demonstrates outstanding customization capabilities, covering various voltage levels such as 60V, 800V, 1200V, 1500V, 2000V, and 2400V. This full voltage range customization ability enables the products to be widely adapted to different application scenarios.

In new energy vehicles, the voltages of battery packs vary. For example, some small electric vehicles may adopt a relatively low 60V battery system, while large electric buses or high-performance electric vehicles may use 800V or even higher-voltage battery packs. The high-power bidirectional DC/DC converters of Shanghai Wenlida can be customized according to the battery voltages of different vehicle models, achieving efficient and stable power conversion between the battery and the vehicle's electrical system. Whether it is the process of obtaining power from the grid and storing it in the battery during charging or supplying power from the battery to the vehicle's motor and other devices during discharging, the converter can precisely control to ensure the safety and stability of power transmission.

The application scenarios of energy storage systems are diverse, including distributed photovoltaic power generation energy storage, wind power generation energy storage, and peak-valley electricity energy storage in industrial enterprises. Different energy storage battery types (such as lead-acid batteries, lithium-ion batteries, etc.) and different application scales have specific requirements for the input and output voltages of DC/DC converters. For some distributed photovoltaic power generation projects, multiple series-connected photovoltaic panel arrays may be used, and their output DC voltages can vary from several hundred volts. The voltage of the energy storage battery may be 1200V, 1500V, etc., depending on the capacity and configuration. Wenlida's bidirectional DC/DC converters can be customized to adapt to these different voltage combinations, efficiently storing the excess power generated by photovoltaic power generation into the battery. When the power consumption is high or the photovoltaic power generation is insufficient, the power in the battery can be stably released to the grid or load, achieving two-way and flexible energy flow.

In smart grid and microgrid systems, there are devices and lines with various voltage levels. For example, the voltage of high-voltage DC transmission lines can be as high as several thousand volts, while the voltages of distributed power sources (such as small wind turbines, home photovoltaic panels) and local loads (such as residential electrical equipment, small industrial equipment) connected to the microgrid are relatively low. The high-power bidirectional DC/DC converters of Shanghai Wenlida can build a bridge between devices with different voltage levels, realizing power conversion and distribution. Between high-voltage DC and low-voltage DC systems, through customized converters, two-way power conversion can be carried out safely and efficiently, ensuring the optimal configuration and stable transmission of energy in smart grids and microgrids.

Powerful Customization Features

In addition to full voltage range customization, the high-power bidirectional DC/DC converters of Shanghai Wenlida also have a series of powerful customization features.

In distributed power generation systems (such as solar photovoltaic power generation systems), the output power of photovoltaic panels fluctuates with changes in environmental factors such as light intensity and temperature. The MPPT function of the converter can monitor the output power of the photovoltaic panels in real-time and adjust its own operating parameters to make the photovoltaic panels always work near the maximum power output point, thereby maximizing the photovoltaic power generation efficiency. When the requirements of the power generation system change or the battery state reaches certain conditions, the converter can automatically switch to the constant voltage mode to provide a stable voltage output for the load or battery. This automatic switching function does not require manual intervention, greatly improving the intelligence and stability of the power generation system.

In the scenarios of electric vehicle charging or energy storage battery charging, different battery types and charging states require different charging modes. The bidirectional DC/DC converters of Shanghai Wenlida can automatically judge the battery type, remaining power, and current charging state through built-in intelligent algorithms and sensors, and then select the most suitable charging mode. For lithium-ion batteries, a constant current charging mode may be adopted when the power is low to quickly replenish the power. When the power is close to full, it will switch to the constant voltage charging mode to prevent overcharging and damage to the battery. For lead-acid batteries, there are unique charging modes adapted to them. This function of automatically judging the charging mode improves the safety and efficiency of charging and extends the service life of the battery.

As a bidirectional DC/DC converter, its core advantage lies in the ability to achieve high-efficiency two-way power transmission. During forward conversion, for example, when converting a high-voltage DC power source into a low voltage to supply power to the load, the converter adopts advanced topological structures (such as bidirectional full-bridge topology, bidirectional half-bridge topology, etc.) and control strategies. By optimizing the conduction and cut-off sequence of the switching tubes, switching losses and conduction losses are reduced, and the power conversion efficiency is improved. During reverse conversion, such as feeding back the power generated by the load or the power discharged by the battery to the high-voltage DC power source system, it can also quickly and stably achieve reverse power flow. Through precise calculation and selection of component parameters such as inductors and capacitors, working in coordination with the topological structure, it ensures high efficiency and stability during the two-way conversion process, with a conversion efficiency of over 98% (such as the 1000kW/3000A bidirectional DC/DC system used in the 1MW/3MW@10S grid-forming energy storage project).

To ensure the safe and stable operation of the equipment under various complex working conditions, the high-power bidirectional DC/DC converter is equipped with multiple protection mechanisms. It has an overvoltage protection function. When the detected input or output voltage exceeds the set safety threshold, it will immediately take measures to limit the voltage to prevent the equipment from being damaged due to overvoltage. The undervoltage protection will cut off the circuit in a timely manner or adjust the working state when the voltage is too low to avoid abnormal operation of the equipment under low voltage. The overcurrent protection can act quickly when the current is too large to protect the internal circuit components. The overtemperature protection monitors the temperature of key parts inside the equipment. When the temperature is too high, it will start the cooling fan or reduce the power operation to prevent performance degradation or component damage caused by overheating. At the same time, the converter also supports intelligent monitoring. It can achieve high-speed data transmission through communication interfaces such as RS485 (Modbus RTU) and CAN2.0A/B, and upload the operating status of the equipment (such as voltage, current, temperature, power and other parameters) to the monitoring center in real-time, facilitating remote monitoring and management by users and also making it easy to detect faults and handle them in a timely manner.

With its profound technical accumulation, rich R&D and industrial experience in the field of high-power bidirectional DC/DC, and accurate grasp of customer needs, Shanghai Wenlida Power Electronics Co., Ltd. provides customized and high-performance power conversion solutions for various industries. Whether in the fields of new energy vehicles, energy storage systems, or smart grids, the company's products demonstrate excellent performance and reliability, strongly promoting the development and progress of the industry.