PCS2: Bidirectional on-board charger for vehicle-to-grid
The work
Heavy wire-wound magnetics gave way to planar magnetics, and electrolytic capacitors to film and ceramic types. Rameez owned the electro-mechanical design of the planar magnetics thermals and the high-voltage creepage and clearance criteria that keep those changes safe at 800 V.
He redesigned the connectors, nano-crystalline chokes and busbars so they could run through an SMT process, ran thermal simulations on the magnetics and structural FEA on the plastics and busbars for vehicle loads, and integrated the connector interfaces into Cybertruck packaging. The nano-crystalline core design for the AC and DC 1 kV chokes, with busbars and connectors integrated, became a patent.
Watch
Moving On Up: Exploring the Cybertruck’s Power Conversion System & 48V Architecture
Tesla PCS2 Cybertruck launch edition, front and back of PCBA
Image: sourced from public teardown websites
1 kV high-voltage connector with integrated choke
Image: sourced from public teardown websites
Tesla PCS2 inside Cybertruck
Image: sourced from public teardown websites
ANSYS thermal simulation example.
Image: recreated with AI as an illustrative example