Just some quick details about Tesla's 2nd Gen onboard charger.
There is a US and European version, which are probably the same (although there might be firmware differences). Sticker of the US version:
Internally it is very different from the 1st Gen, which was a bit bodged together. I can post some photos of it as well, even though I expect that most people will see the 2nd gen in the incoming years. On the 2nd gen, you can clearly see three long PCB segments under plastics, that looks remarkably similar to each other. On the top the small board is the controller, providing high level control of those three blocks:
The ugly snots is not a glue, but some silicone for isolation of HV pins. Probably a design afterthought. All boards have standard Tesla epoxy coating. Power sections are hidden under, bathing in clear semi-solid sticky goo (IGBT fill material)
Three sections exposed. Each one is an independent ~3.7kW fully isolated charger. Their outputs are connected in parallel to triple the output current. Inputs (AC side) are either in parallel as well (the US version), to provide 240VAC input at high current (48A RMS), or split as one module per phase (for countries that do know that 3 phase system is better than single phase). There each charger is between phase and neutral, seeing 230V ~16A on each input. Since the chargers are isolated, they can do this scheme and not to bother with more versions for different grid systems.
I'll post more later when I dissect the rest.
NOTE: These are my opinions only, and in some cases I'm speculating. Feel free to correct me.
There is a US and European version, which are probably the same (although there might be firmware differences). Sticker of the US version:
Internally it is very different from the 1st Gen, which was a bit bodged together. I can post some photos of it as well, even though I expect that most people will see the 2nd gen in the incoming years. On the 2nd gen, you can clearly see three long PCB segments under plastics, that looks remarkably similar to each other. On the top the small board is the controller, providing high level control of those three blocks:
The ugly snots is not a glue, but some silicone for isolation of HV pins. Probably a design afterthought. All boards have standard Tesla epoxy coating. Power sections are hidden under, bathing in clear semi-solid sticky goo (IGBT fill material)
Three sections exposed. Each one is an independent ~3.7kW fully isolated charger. Their outputs are connected in parallel to triple the output current. Inputs (AC side) are either in parallel as well (the US version), to provide 240VAC input at high current (48A RMS), or split as one module per phase (for countries that do know that 3 phase system is better than single phase). There each charger is between phase and neutral, seeing 230V ~16A on each input. Since the chargers are isolated, they can do this scheme and not to bother with more versions for different grid systems.
I'll post more later when I dissect the rest.
NOTE: These are my opinions only, and in some cases I'm speculating. Feel free to correct me.