Hello again Aisler Community!
Following up on our earlier post about the MCU and lights, here’s another board from our solar car lux025 that Aisler manufactured for us: our HV-LV DC-DC converter board.
This board sits inside our battery pack module and is the lifeline for every piece of electronics on the car. It hosts a Traco full-brick DC-DC converter that steps down from our high-voltage battery bus of 150V to a 24V supply dedicated to driving the battery pack contactors, and then smaller converters step that further down to a 12V rail that powers everything else, from the BMS inside the pack to all the other boards around the car.
One of the main design challenges was thermal management. Since the battery pack is a sealed enclosure, there’s no airflow to help with cooling. The board was designed with large, thick copper pours to spread and sink heat effectively, keeping things running reliably in the Australian outback heat.
Sharp-eyed viewers might spot the “this is fine” dog on the silkscreen, a small reminder of the tight timelines and everything that went wrong along the way. But hey, the boards got made thanks to Aisler’s Express Service and the car made it to Australia.
Thanks again to Aisler for consistently delivering quality boards for us!