{"id":2376,"date":"2026-10-27T08:15:04","date_gmt":"2026-10-27T08:15:04","guid":{"rendered":"https:\/\/ovartech.com\/?p=2376"},"modified":"2026-10-27T08:20:08","modified_gmt":"2026-10-27T08:20:08","slug":"5-critical-pitfalls-to-avoid-when-selecting-an-obc","status":"publish","type":"post","link":"https:\/\/ovartech.com\/ko\/5-critical-pitfalls-to-avoid-when-selecting-an-obc\/","title":{"rendered":"5 Critical Pitfalls to Avoid When Selecting an OBC for 800V High-Voltage Platform Vehicles"},"content":{"rendered":"<h1 style=\"text-align: center;\"><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 18pt;\">5 Critical Pitfalls to Avoid When Selecting an OBC for 800V High-Voltage Platform Vehicles<\/span><\/strong><\/h1>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">When selecting an On-Board Charger (OBC) for 800V high-voltage platform vehicles, the five most common and costly pitfalls are insufficient voltage rating of power devices, inadequate insulation design, underestimating thermal challenges, ignoring efficiency at high voltage, and overlooking charging infrastructure compatibility. Avoiding these issues is essential to ensure safety, reliability, charging performance, and long-term system cost control on 800V architectures.<\/span><\/p>\n<table style=\"border-collapse: collapse; width: 100%;\">\n<tbody>\n<tr>\n<td style=\"width: 100%;\"><a href=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3.jpg\"><img decoding=\"async\" class=\"lazyload aligncenter wp-image-2377 size-fusion-800\" src=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-800x537.jpg\" data-orig-src=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-800x537.jpg\" alt=\"OBC\" width=\"800\" height=\"537\" srcset=\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%27800%27%20height%3D%27537%27%20viewBox%3D%270%200%20800%20537%27%3E%3Crect%20width%3D%27800%27%20height%3D%27537%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" data-srcset=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-18x12.jpg 18w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-200x134.jpg 200w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-300x201.jpg 300w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-400x268.jpg 400w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-500x336.jpg 500w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-600x403.jpg 600w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-700x470.jpg 700w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-768x516.jpg 768w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-800x537.jpg 800w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3-1024x687.jpg 1024w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/khxP3.jpg 1168w\" data-sizes=\"auto\" data-orig-sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/a><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Pitfall 1: Insufficient Voltage Rating of Power Semiconductors<\/span><\/strong><\/h2>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Many 400V-era OBCs use 650V or 900V power devices. On an 800V platform, the DC-link voltage can reach 850\u2013900V under certain conditions, leaving insufficient safety margin.<\/span><\/p>\n<p><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Risks:<\/span><\/strong><\/p>\n<ul>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Device breakdown under voltage spikes or regenerative events<\/span><\/li>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Reduced reliability and higher failure rates<\/span><\/li>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Potential safety hazards<\/span><\/li>\n<\/ul>\n<p><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Correct approach:<\/span><\/strong><\/p>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Select OBCs that use 1200V-class SiC MOSFETs or IGBTs with adequate derating. Wide-bandgap devices are preferred for both voltage capability and efficiency.<\/span><\/p>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Ovar Tech\u2019s high-voltage OBC solutions, including 22kW models designed for elevated voltage platforms, incorporate appropriately rated power devices to maintain robust safety margins on 800V systems.<\/span><\/p>\n<h3><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Pitfall 2: Inadequate Insulation and Isolation Design<\/span><\/strong><\/h3>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Higher system voltage significantly increases the requirements for creepage, clearance, and isolation barriers.<\/span><\/p>\n<p><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Common mistakes:<\/span><\/strong><\/p>\n<ul>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Using isolation transformers or PCBs designed for 400V systems<\/span><\/li>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Insufficient reinforced insulation between primary and secondary sides<\/span><\/li>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Inadequate high-voltage connector and cable ratings<\/span><\/li>\n<\/ul>\n<p><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Consequences:<\/span><\/strong><\/p>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Failure to meet ISO 6469, IEC 60664, or OEM-specific insulation coordination requirements can lead to certification failure or field safety issues.<\/span><\/p>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Designers must verify reinforced insulation, partial discharge performance, and high-potential (Hi-Pot) test results specifically for 800V operation.<\/span><\/p>\n<h4><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Pitfall 3: Underestimating Thermal Management Challenges<\/span><\/strong><\/h4>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Although higher voltage reduces current for the same power, switching losses, magnetic losses, and concentrated heat in power modules can still create serious thermal issues\u2014especially in high-power 11kW or 22kW OBCs.<\/span><\/p>\n<p><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Pitfalls include:<\/span><\/strong><\/p>\n<ul>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Relying on air cooling when liquid cooling is required<\/span><\/li>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Poor cold-plate design or thermal interface materials<\/span><\/li>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Inadequate temperature monitoring and derating strategies<\/span><\/li>\n<\/ul>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">An OBC that performs well on a 400V platform may overheat or require heavy derating on an 800V vehicle if thermal design is not re-validated.<\/span><\/p>\n<h5><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Pitfall 4: Ignoring Efficiency and Power Density at High Voltage<\/span><\/strong><\/h5>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Higher voltage enables lower current and potentially higher efficiency, but only if the topology and components are optimized. Some designs suffer from:<\/span><\/p>\n<ul>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Increased switching losses if gate drive or layout is not optimized for SiC<\/span><\/li>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Higher core losses in transformers at elevated voltage<\/span><\/li>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Larger magnetic components that hurt power density<\/span><\/li>\n<\/ul>\n<p><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Best practice:<\/span><\/strong><\/p>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Demand efficiency maps across the full voltage and load range, not just peak efficiency numbers. Look for soft-switching topologies (LLC, CLLC, or advanced resonant designs) proven on 800V platforms.<\/span><\/p>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Ovar Tech\u2019s high-voltage OBC portfolio focuses on high efficiency and compact packaging suitable for modern 800V electric vehicles.<\/span><\/p>\n<h6><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Pitfall 5: Overlooking Charging Infrastructure and Communication Compatibility<\/span><\/h6>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">An 800V vehicle must still charge reliably on both 400V and 800V DC fast chargers as well as AC infrastructure. The OBC itself mainly handles AC charging, but system-level compatibility is critical.<\/span><\/p>\n<p><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Key issues to check:<\/span><\/strong><\/p>\n<ul>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Correct handling of AC input voltage range and power factor under high DC-link voltage<\/span><\/li>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Proper communication (ISO 15118, DIN 70121) and voltage negotiation when the vehicle also supports DC fast charging<\/span><\/li>\n<li><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Smooth transition between AC and DC charging modes without bus voltage conflicts<\/span><\/li>\n<\/ul>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Selecting an OBC without verifying full system compatibility can result in limited charging speed or interoperability problems in the field.<\/span><\/p>\n<table style=\"border-collapse: collapse; width: 100%;\">\n<tbody>\n<tr>\n<td style=\"width: 100%;\"><a href=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV.jpg\"><img decoding=\"async\" class=\"lazyload wp-image-2387 size-fusion-800 aligncenter\" src=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-800x537.jpg\" data-orig-src=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-800x537.jpg\" alt=\"\" width=\"800\" height=\"537\" srcset=\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%27800%27%20height%3D%27537%27%20viewBox%3D%270%200%20800%20537%27%3E%3Crect%20width%3D%27800%27%20height%3D%27537%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" data-srcset=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-18x12.jpg 18w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-200x134.jpg 200w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-300x201.jpg 300w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-400x268.jpg 400w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-500x336.jpg 500w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-600x403.jpg 600w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-700x470.jpg 700w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-768x516.jpg 768w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-800x537.jpg 800w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV-1024x687.jpg 1024w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/RrfHV.jpg 1168w\" data-sizes=\"auto\" data-orig-sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/a><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>&nbsp;<\/p>\n<p><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Summary of the Five Pitfalls<\/span><\/strong><\/p>\n<table style=\"border-collapse: collapse; width: 100%;\">\n<tbody>\n<tr>\n<td style=\"width: 100%;\"><a href=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2.jpg\"><img decoding=\"async\" class=\"lazyload wp-image-2390 size-fusion-800 aligncenter\" src=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-800x450.jpg\" data-orig-src=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-800x450.jpg\" alt=\"\" width=\"800\" height=\"450\" srcset=\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%27800%27%20height%3D%27450%27%20viewBox%3D%270%200%20800%20450%27%3E%3Crect%20width%3D%27800%27%20height%3D%27450%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" data-srcset=\"https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-18x10.jpg 18w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-200x113.jpg 200w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-300x169.jpg 300w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-400x225.jpg 400w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-500x281.jpg 500w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-600x338.jpg 600w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-700x394.jpg 700w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-768x432.jpg 768w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-800x450.jpg 800w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-1024x576.jpg 1024w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2-1200x675.jpg 1200w, https:\/\/ovartech.com\/wp-content\/uploads\/2026\/10\/image-2.jpg 1280w\" data-sizes=\"auto\" data-orig-sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/a><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>&nbsp;<\/p>\n<p><strong><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Conclusion<\/span><\/strong><\/p>\n<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Moving to an 800V architecture brings clear benefits in charging speed, cable weight, and efficiency, but it also raises the technical bar for the On-Board Charger. The five pitfalls outlined above\u2014voltage rating, insulation, thermal design, efficiency optimization, and infrastructure compatibility\u2014are the most frequent sources of costly redesigns and field issues.<\/span><br \/>\n<span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">By carefully evaluating these areas and selecting proven high-voltage solutions, such as those offered by Ovar Tech for elevated voltage platforms, vehicle manufacturers can fully realize the advantages of 800V systems while maintaining safety, reliability, and competitive cost.<\/span><\/p>","protected":false},"excerpt":{"rendered":"<p>5 Critical Pitfalls to Avoid When Selecting an OBC for  [&#8230;]<\/p>","protected":false},"author":2,"featured_media":2377,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"content-type":"","footnotes":""},"categories":[17,126],"tags":[209],"class_list":["post-2376","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news","category-tips-tricks","tag-obc"],"acf":[],"_links":{"self":[{"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/posts\/2376","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/comments?post=2376"}],"version-history":[{"count":16,"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/posts\/2376\/revisions"}],"predecessor-version":[{"id":2395,"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/posts\/2376\/revisions\/2395"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/media\/2377"}],"wp:attachment":[{"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/media?parent=2376"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/categories?post=2376"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/ovartech.com\/ko\/wp-json\/wp\/v2\/tags?post=2376"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}