400A~800A Fast EV Charger Cable Cooling Pump Solution

The biggest problem of electric vehicles as the preferred choice of environmentally friendly transportation is the slow charging speed for long-distance running, so super fast charging is the mainstream development demand of EV Charger research at present.

To meet market demands, high-current liquid-cooled charger have evolved from the initial 280A to now supporting much higher currents 600A+.

In the EV charger industry, to meet the cooling requirements of different electric vehicle charging cables, an effective cooling system for managing the heat generated during the charging process is crucial.

How to Design an Efficient Cooling Solution for?Fast Charging Cables?

1. Understanding Heat Generation:

The heat generated by the cable can be calculated using the following formula:?Q=I2Rt?, where:

• Q?represents the heat generated by the cable, in joules (J).
• I?represents the current through the cable, in amperes (A).
• R represents the resistance of the cable, in ohms (Ω).
• T?represents the time the current passes through the cable, in seconds (s).

It is evident that the heat generated by the cable is proportional to the square of the current, the resistance, and the duration the current flows through the cable.

The heat effect increases significantly with high currents. Understanding the heat generated during high-current charging allows for matching the optimal and most cost-effective cooling method, preventing the accumulation of large amounts of heat in cables and connectors due to high currents.

2. Choosing the Right Cooling Method:

The working conditions of EV Charger?are increasingly complex and diverse, such as desert, tropical, seaside, mining areas, etc., bringing high temperature, high humidity, high salt, and dusty working environment, which brings great challenges to the operation and maintenance of charging facilities.

Based on the heat generation calculations, select a cooling method that efficiently dissipates the generated heat. Common cooling methods include:

• Air Cooling:??Traditional piles rely on air heat exchange to cool down,?suitable for lower heat dissipation requirements. It uses fans or blowers to move air across the cables and components, dissipating heat through convection.?But the internal components are not isolated: the circuit board and power devices in the charging module are in direct contact with the external environment, which is easy to cause module failure. Wet dust and high temperature cause the annual failure rate of modules to be as high as 3-8%, or even higher.?

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• Liquid Cooling:??the use of full isolation protection, through the coolant and radiator heat exchange, completely isolated from the external environment, extend the service life of the equipment, so the reliability is much higher than the air cooling. More effective for higher heat dissipation needs. It involves circulating a coolant (usually water or a water-glycol mixture) through a system of tubes or channels in direct contact with the cables, absorbing heat and transporting it away from the heat source.

3. Design cooling system:

the liquid-cooled EV charger needs to be equipped with a cooling unit, which is composed of a water tank, cooling water pump, radiator and fan. The cooling water pump drives the coolant to circulate in the EV charger cable, bringing heat to the radiator, which is then blown away by the fan, thus achieving greater current carrying capacity than conventional naturally cooled EV charger. Choose a rugged cooling pump that circulates the coolant through the cable. Finding a water pump that can handle the flow required for effective cooling at high currents is critical.

400 ~ 500A cable cooling water pump -- TOPSFLO centrifugal water pump coolant solution: TA70E-A24-4030

PWM speed regulation and FG signal feedback can be customized,

The price is half of the gear pump, with low power consumption, long life and noise level of about 58dB@1 meter.

500A ~ 800A cable cooling water pump -- TOPSFLO gear pump insulation oil solution:TMG317XK/DC24DM

- Coolant: Choose the right coolant so that it can effectively transfer heat away from the cable. Water-based coolants with additives for corrosion protection and thermal conductivity enhancement are a common choice.

- Cooling path: Plan the path for the coolant to pass through the cable. Make sure to cover areas where heat build-up is most significant, such as conductors and connectors.

4. Coolant storage and radiator:

- Reservoir: Includes a reservoir to hold the coolant. This allows the coolant system to be replenished and extended.

- Radiator: Integrates a radiator to dissipate heat absorbed by the coolant. The radiator can be air-cooled or liquid-cooled depending on your setup and space constraints.

5. Pump control and monitoring:

- Control system: According to the filling rate and temperature sensor, the control system of the pump is realized to adjust the coolant flow.

- Temperature monitoring: Install temperature sensors along the length of the cable to monitor heat levels. This data can be used to adjust pump speed and optimize cooling.

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6. Safety and reliability:

- Redundancy: Consider redundancy of critical components such as pumps and sensors to ensure continuous operation and safety.

- Leak detection: A leak detection mechanism is adopted to prevent coolant leakage and affect the integrity of the charging cable.

7. Test and verification:

Prototype testing: Build and test prototypes of cooling systems under various load conditions to ensure their effectiveness and reliability.

- Performance verification: Verify the performance of the cooling system according to safety standards and operational requirements.

8. Installation and maintenance:

- Installation: Ensure that the cooling system is properly installed within the charging infrastructure.

Maintenance: Develop a maintenance plan for regular inspection, fluid replacement, and system troubleshooting.

With the above steps, you can design and implement an effective cooling pump solution for high-current EV charging cables, ensuring efficient thermal management and reliable operation during high-current charging.

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