How to Choose the Suitable On-Board Charger for the Electrification Conversion of Wuling Journey MPV? (6.6kW OBC with CAN Support)
The electrification conversion of the Wuling Journey MPV is a transformative project that replaces the traditional internal combustion engine with a modern electric powertrain. A critical component in this upgrade is the on-board charger (OBC), responsible for converting AC grid power into DC power to charge the high-voltage battery pack. For optimal performance, reliability, and integration, selecting a 6.6kW OBC with CAN communication capability is highly recommended. Here’s how to choose the right one.
- Power Rating: Match Charging Speed to Battery Capacity
A 6.6kW OBC is ideal for the Wuling Journey MPV conversion, offering a balanced charging speed suitable for daily use. With the 120kW 3-in-1 powertrain operating on a 385V DC platform (290–480V range), the OBC must deliver sufficient current to charge the battery efficiently—typically within 4–6 hours depending on battery size. This power level is compatible with standard Level 2 charging stations (220V AC, 32A), making it practical for home and public charging.
- CAN Communication: Essential for System Integration
The 3-in-1 powertrain uses CAN bus protocol to monitor and control motor, controller, and thermal data. Your OBC must support CAN communication to interface with the vehicle’s existing network. This allows:
- Real-time charging status updates (e.g., current, voltage, state of charge)
- Fault diagnostics and error code reporting
- Coordination with the battery management system (BMS) and motor controller
- Synchronization of charging enable/disable signals
Ensure the OBC supports standard CAN 2.0B protocol and can be configured to match the vehicle’s CAN ID structure. Some advanced OBCs allow custom CAN message mapping, which is crucial for seamless integration.
- Input and Output Specifications
The OBC should have:
- AC Input:220V AC (±10%), 50Hz, single-phase (standard in most regions)
- DC Output:Adjustable voltage range (ideally 290–480V DC) to match the battery’s operating window
- Max Output Current:~17A (for 6.6kW at 385V)
Verify that the OBC can auto-detect charging cable capacity (e.g., 16A vs. 32A) and supports safety features like ground fault detection and overcurrent protection.
- Efficiency and Thermal Management
Look for an OBC with efficiency ≥90% to minimize energy loss during conversion. Since the powertrain is liquid-cooled, consider an OBC with built-in liquid cooling or at least IP67-rated housing for dust and water resistance. If liquid cooling isn’t available, ensure the OBC has robust fan cooling and thermal derating features to prevent overheating in confined spaces.
- Protection and Durability
The OBC must meet IP67 protection level to withstand moisture and dust, especially in under-hood or underbody installations. It should also include:
- Overvoltage, overcurrent, and short-circuit protection
- Reverse polarity protection
- Insulation monitoring (especially important with high-voltage systems)
- Compliance with automotive safety standards(e.g., ISO 6469, IEC 61851)
- Physical Size and Mounting
The Wuling Journey MPV has limited space, so choose a compact, lightweight OBC that fits in available areas (e.g., front compartment, under seats). Ensure there’s enough clearance for cooling and cable routing. Mounting brackets or rubber dampeners help reduce vibration stress.
- Compatibility with Battery and BMS
The OBC must communicate effectively with the Battery Management System (BMS) to follow charging curves (CC/CV), monitor cell voltage, temperature, and prevent overcharging. Confirm that the OBC supports BMS handshake protocols via CAN, and that charging will stop automatically when SOC reaches 100% or if temperatures exceed safe limits (e.g., PT1000 sensor readings).
- Safety Certifications and Reliability
Choose an OBC certified by CE, FCC, or E-Mark, indicating compliance with electromagnetic compatibility and safety regulations. Given the vehicle’s design life of 20 years or 300,000 km, opt for industrial or automotive-grade units with proven longevity, not consumer-grade adapters.
- Ease of Installation and Diagnostics
A user-friendly OBC should have:
- Clear labeling of terminals (L, N, PE, DC+, DC-)
- Built-in OBD2 or CAN diagnostic portfor troubleshooting
- LED indicators for power, charging, and fault status
- Support for remote monitoringvia app or cloud platform (optional but valuable)
- Brand and Support
Select from reputable manufacturers specializing in EV conversion components. Look for products with detailed technical documentation, firmware update support, and responsive customer service. Open-source or community-supported OBCs often have active forums for troubleshooting.
Conclusion
Choosing the right 6.6kW OBC with CAN support is vital for a safe, efficient, and integrated electrification conversion of the Wuling Journey MPV. Prioritize CAN compatibility, safety features, thermal management, and reliability to ensure seamless communication with the 120kW 3-in-1 powertrain and a smooth, modern driving experience. With the correct OBC, your electric MPV will charge efficiently, operate safely, and stand the test of time.
