How Electronics is Changing Motoring

2019. 7. 10
The Formula Student Electric (FSE) racing car, featuring RECOM DC/DC converters
No doubt about it, cars have changed the world over the past century. However, the trend toward ever-faster and larger models has shifted. Climate change and dwindling resources have driven innovation in alternative propulsion systems. Electric power is now central in defining a car’s performance, with new applications emerging for modular power converters.

Table of contents

The Formula Student Electric (FSE) racing car developed at the University of Munich has six highly isolated RECOM DC/DC converters on each wheel, supplying power to critical vehicle electronics. (Photo: MunicHMotorsport)

Range and Charging Infrastructure

Current lithium-ion batteries struggle to provide the range required for long trips, particularly in extreme temperatures where climate control is necessary. Fast-charging infrastructure remains sparse, especially in rural areas. Even at existing stations, charging can take nearly an hour—far from the convenience of refueling a combustion engine vehicle.

Cost Barriers

Despite government incentives, EVs remain expensive for most consumers. Electricity costs in Germany further limit savings, making EVs less appealing compared to fuel-efficient diesel vehicles.

Battery Longevity and Environmental Impact

While EVs reduce maintenance costs, battery degradation is a major concern. After a few years, the replacement cost can significantly devalue an EV. Moreover, battery production and raw material extraction generate substantial emissions, challenging the perception of EVs as completely eco-friendly.

Voltage Converters: The Core of EV Charging

Electric car is being charged at a charging station
Fig. 1: Voltage converters in charging stations provide the high levels of isolation needed.
Before an EV can hit the road, charging circuits convert AC grid power into high-voltage DC while monitoring the charging process.
  • Standard Home Charging: A 230V household outlet can fully charge a small EV overnight.
  • Fast-Charging Stations: Public stations deliver 100kW+, taking about one hour to charge an 85kWh battery.
  • Ultra-Fast Charging: Emerging 400kW systems could cut charging time to 15 minutes.

With high-voltage systems, safety and isolation are critical. EVs communicate with charging stations to regulate power flow. If the connection fails, the system automatically disconnects. The RECOM RAC05-xxSK/480 was developed for this monitoring role.

Battery Management Systems (BMS) and Isolation

Advanced lithium-ion battery packs are composed of multiple modules, each requiring independent monitoring of current, voltage, and temperature. RECOM’s isolated DC/DC converters enable safe operation by providing high-voltage isolation between the monitoring electronics and the vehicle’s CAN bus.

DC/DC converters also play a role in power semiconductor control, supplying IGBT, SiC, and GaN gate drivers with isolated voltage.

  • IGBT: +15V / -9V
  • SiC: +15V / -3V, +20V / +5V
  • GaN: +6V / +9V

Innovation Through Motorsport

Motorsport serves as a proving ground for new technologies. Formula E has dramatically improved battery efficiency, now completing races on a single charge.

Universities like the Technical University of Munich are also advancing EV technology. Their Formula Student Electric (FSE) race car, developed with MunicHMotorsport, features twenty-four RECOM RxxP2xx DC/DC converters powering the control electronics.

IGBT-, SiC- und GaN-Treiber
Fig. 2: Highly isolated DC/DC converters supply IGBT, SiC, and GaN drivers.

Looking Ahead: The Future of E-Mobility

Ongoing research is exploring next-generation battery technology:
  • Solid-State Batteries: More stable, durable, and resource-efficient
  • Hydrogen Fuel Cells: Researchers at Friedrich Alexander University Erlangen are working on liquid organic hydrogen carriers (LOHCs), offering safe, flammable-free fuel storage

Regardless of the power source, electric propulsion, monitoring, and communication systems will remain essential. This creates a growing demand for highly efficient voltage converters, positioning RECOM at the forefront of e-mobility innovation.

RECOM: We Power your Products
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  Series
1 AC/DC, 5 W, Single Output, THT RAC05-K/480 Series
Focus
  • Ultra-wide input range 85-528VAC
  • OVC III input rating without additional fuses
  • Operating temperature range: -40°C to +80°C
  • Overvoltage and overcurrent protected
2 DC/DC, 2 W, THT RxxP2xx Series
  • Qualified with 65kV/µs @ common mode =1KV
  • Isolation 6.4kVDC
  • Optional continuous short circuit protection
  • Unique transformer system