Power Conversion Engineering
High-reliability onboard chargers, bidirectional DC/DC converters, and off-board fast charging power modules engineered for global EV OEMs, commercial fleets, and charging infrastructure.
Wall Industries offers a specialized catalog of high-efficiency AC/DC power supplies and DC/DC converters built to handle the severe ambient environments, continuous thermal stress, and stringent electrical safety demands of modern electric vehicles (EVs) and charging systems.
| Series Model | Input Voltage Range | Output Voltage Options | Output Power Rating | Primary Application & Package Format |
|---|---|---|---|---|
| PSEOCH05 | 90 – 305 VAC (115/230 VAC nominal) | 3.3V, 5V, 12V, 24V DC | 5 W – 5.04 W | Ultra-compact encapsulated PCB module (1.46” x 1.08” x 0.69”) for logic, sensors, and control boards. |
| PSAOD10 | 100 – 240 VAC (47–63 Hz) | 3.3V, 5V, 12V, 15V, 24V DC | 10 Watts | Encapsulated ITE power module for standby power, smart charging station interface, and control modules. |
| DCVK168 | Wide-range DC Input Bus | Custom Regulated DC Rails | 168 Watts | Ruggedized conduction-cooled chassis converter (4.76” x 3.79” x 1.44”) with multi-wire harness for onboard systems. |
| PSAEK3000HV-OR | Universal High-Voltage AC Input | High-Voltage Regulated DC | 3,000 Watts | High-power enclosed power supply (11.02” x 6.69” x 2.52”) for industrial chargers and high-voltage DC buses. |
| PSEV3600 | Universal AC Mains Input | Programmable Battery Output | 3,600 Watts | High-power AC/DC battery charger module (12.4” x 7.08” x 5.12”) equipped with active fan cooling and handle. |
Modern electric drive platforms rely on highly synchronized power electronic modules to convert, regulate, and distribute electrical energy between storage units, traction drives, and auxiliary networks.
Converts single-phase or three-phase AC power from utility grids into regulated DC energy to charge the high-voltage main battery pack. Our designs feature power factor correction (PFC) exceeding 0.99 and peak efficiencies above 96%.
Steps down high-voltage traction battery power (typically 400V or 800V) to low-voltage DC rails (12V, 24V, or 48V) to continuously power vehicle control units (VCU), infotainment, safety actuators, and brake-by-wire subsystems.
Converts DC energy stored in the main battery pack into precise, sinusoidal multi-phase AC power to drive traction motors during acceleration, while converting kinetic braking energy back into DC storage during regenerative deceleration.
Delivers direct, high-power DC current directly to the EV battery, bypassing onboard conversion bottlenecks. Requires robust isolation transformers, modular scalable power blocks, and intelligent communication protocols.
Provides stable, low-noise, highly isolated power rails for voltage sensor arrays, microcontroller logic, and active cell-balancing switches operating across high common-mode potential differentials.
Utilizes IP67/IP68 liquid cooling baseplates or potting compounds to prevent thermal degradation, insulation breakdown, and liquid ingress caused by salt spray, rain, or thermal shock cycles.
In advanced e-mobility architectures, bidirectional power conversion is critical for vehicle-to-grid (V2G) power sharing and energy recovery. Wall Industries designs power supplies with isolated transformer barriers rating up to 3,000–5,000 VAC, safeguarding low-voltage microcontrollers and vehicle occupants from high-voltage transients.
Our power converters undergo rigorous isolation, creepage, and clearance verification under IEC 60664-1 standards to ensure immunity against high dv/dt switching noise generated by modern Wide Bandgap (SiC and GaN) semiconductor topologies.
Vehicle-mounted power conversion components must withstand severe mechanical shock, vibration, and continuous operational temperature swings. Wall Industries incorporates conformal coating, potting compounds, and heavy-duty aluminium enclosures engineered to meet ISO 26262 functional safety concepts and CISPR 25 Class 5 EMC emission boundaries.
From prototype engineering to full multi-year series production, every design is subjected to functional test screening, high-temperature burn-in, and full thermal characterization prior to delivery.
With over six decades of power conversion engineering expertise based in Exeter, New Hampshire, USA, Wall Industries offers global original equipment manufacturers (OEMs) direct access to dedicated power design teams. Whether you require a catalog platform modified for specialized output voltages and connectors, or a completely ground-up custom automotive power assembly, our engineering team ensures fast qualification turnaround, transparent compliance documentation, and long-term lifecycle availability.
Electric vehicle power systems convert energy stored in high-voltage battery packs into appropriate voltage levels for traction drives (via DC/AC inverters) and low-voltage auxiliary equipment such as ECU, lighting, and HVAC (via isolated DC/DC step-down converters).
Bidirectional power converters facilitate two-way energy flow between the battery pack and the traction motor drive. They deliver energy during acceleration and capture kinetic energy during regenerative braking to charge the high-voltage battery bank.
AC Level 2 charging relies on an onboard charger (OBC) to convert AC grid power to DC for the battery. DC Fast Charging bypasses the onboard charger, delivering regulated high-power DC directly to the vehicle battery pack for rapid energy replenishment.
EV power modules exposed to external weather conditions require IP67/IP68 water ingress protection, conformal coating, potted encapsulation, and wide operational thermal ranges (-40°C to +85°C) to withstand shock, vibration, moisture, and road debris.
Yes. A major portion of our OEM deliveries consists of modified-standard solutions. We adjust output voltage trimming, cable harness configurations, potting density, thermal baseplates, and mechanical enclosure dimensions while preserving proven core circuit topologies.
Discuss your electrical voltage ranges, mechanical constraints, thermal specifications, and compliance targets with our US-based power applications engineering team.