High Voltage Heater Automotive for Electric Vehicle

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High-Voltage Automotive Heater for Electric Vehicles

 

 

Power (KW)	3KW
Rated voltage(V)	350V
Supply voltage (V)	260-420V
Flow rate (L/h)	12 (±1)L/min
Baud rate	250K
Working temperature	-40℃~85℃
storage temperature	-40℃~85℃
Control	CAN

 

 

Internal assembly

 

PTC ceramic heating stack + insulating thermal-conductive layer + aluminum alloy housing with integrated coolant channels + control board (IGBT + MCU) + high/low-voltage connectors, temperature sensors, and a high-voltage interlock circuit.

The VCU/BMS issues heating commands via CAN/LIN; a 12V low-voltage supply powers the control board, while the high-voltage traction battery powers the PTC heating elements.

The MCU manages the switching of IGBT groups to enable multi-stage power regulation (e.g., 3kW, 5kW, 7kW, 10kW, etc.).

Coolant (ethylene glycol-based antifreeze) enters through the inlet and flows through the channels surrounding the PTC core, absorbing heat.

The heated coolant exits the unit and is circulated by an electronic water pump to the battery cooling plate and the cabin heater core.
Onboard NTC sensors monitor the temperatures of the medium and the housing, as well as the bus current, to facilitate closed-loop protection-covering overvoltage, undervoltage, overcurrent, overtemperature, insulation faults, and high-voltage interlock disconnections.

 

Advantages

Features inherent self-limiting temperature safety characteristics; power output automatically decreases if overheating occurs, providing a higher safety margin than standard resistive heating wires.

Rapid startup and immediate heat generation upon activation; provides stable heating in low-temperature environments (unlike heat pumps, which experience significant performance degradation below -10°C, PTC heaters remain unaffected by low temperatures).

Power output can be adjusted continuously across multiple levels, supported by mature control strategies.

Simple, reliable design with a proven track record, facilitating shorter vehicle validation cycles.

Liquid-cooled versions offer multi-functional utility-capable of simultaneously preheating the battery and warming the cabin-ensuring a high level of thermal management integration.

No open flames or exposed glowing heating elements, making it well-suited for the enclosed space of a vehicle cabin.

 

 

 

 

New Energy Passenger Vehicles

Preheating of traction batteries (a core function of the Battery Thermal Management System, or BTMS): Enhances cell activity at low temperatures, enables fast charging, and preserves battery lifespan.

 

Heating for the passenger cabin (providing warm air during winter).

 

Plug-in Hybrid Electric Vehicles (PHEVs): Supplies heat to the electric drive circuit, battery, and cabin when the internal combustion engine is shut off.

 

Supplementary heating for heat pump systems: Acts as an auxiliary heat source (via PTC heating) when the heat pump's capacity is insufficient during extreme cold weather.

 

New Energy Commercial Vehicles: Electric buses, heavy-duty trucks, sanitation vehicles, and logistics vehicles.

 

Preheating of high-capacity battery packs and heating for the driver's cab.

 

High power output, typically ranging from 8 to 15 kW; many models utilize two separate PTC heating units-one dedicated to the battery and the other to the cabin.

 

List of Associated Components

Electric Water Pump

Operating Logic: The Vehicle Control Unit (VCU) issues a heating command → the PTC heater activates, and the electric water pump simultaneously starts circulating the coolant. If the water pump stops, the PTC heater will typically trigger a "dry-run" protection mechanism, resulting in reduced power output or a complete shutdown. The hydronic (water-based) PTC heater and the electric water pump function as an integrated thermal circuit and can be offered as a bundled solution.

 

Electric Compressor (for Heat Pump Systems):

Complements the PTC heater within a heat pump air conditioning system.

 

Three-way/Four-way Valves and Water Valves:

Used for circuit switching and distributing thermal energy to either the battery pack or the vehicle cabin.

 

 

 

 

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