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Liquid Cooling Electric Vehicle (EV) Rapid Chargers

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Liquid Cooling Electric Vehicle (EV) Rapid Chargers

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Introduction to Liquid Cooling Rapid Chargers

Liquid Cooling Rapid Chargers are a high-power fast charging technology mainly used in the charging process of electric vehicles. This technology uses a liquid cooling system to provide higher charging power and faster charging speeds to meet user needs for electric vehicle charging times.
The basic principle of liquid cooling overcharging is to apply a liquid cooling medium (usually a liquid coolant) to charging equipment, such as charging piles or battery packs for electric vehicles. During the charging process, the liquid cooling medium is connected to the charging equipment or battery pack through passages and heat dissipation systems, effectively absorbing and dissipating the heat generated by charging.

Features of Liquid Cooling Rapid Chargers:

1. Provide high-power charging: Through liquid cooling technology, higher charging power can be provided, thereby shortening charging time. Compared with traditional air cooling technology, Liquid Cooling Rapid Chargers can provide greater current to the battery in a short period of time to achieve fast charging.

2. Control temperature: The liquid cooling system can effectively control the temperature during charging and prevent the battery from overheating, thereby improving charging efficiency and extending battery life.

3. Provide stability and reliability: The liquid cooling system can provide a more stable operating temperature for the battery and maintain the stability and reliability of the charging process.

It should be noted that Liquid Cooling Rapid Chargers technology requires charging equipment and battery systems to have corresponding liquid cooling systems and other hardware components. These devices often require special design and engineering to accommodate the requirements of liquid cooling technology.

The development of Liquid Cooling Rapid Chargers technology helps increase the charging speed and flexibility of electric vehicles, making electric vehicles more feasible and competitive. However, the application of liquid-cooled overcharging is still developing, and related technologies and equipment still need to be continuously optimized and improved to meet the growing demand for electric vehicles.


Liquid Cooling Electric Vehicle (EV) Rapid Chargers


Advantages of Liquid Cooling Rapid Chargers

1) Larger current and fast charging speed. The output current of the charging pile is limited by the charging gun wire. The copper cable inside the charging gun wire conducts electricity, and the heat generated by the cable is proportional to the square value of the current. The greater the charging current, the greater the heat generated by the cable. It must be reduced. To avoid overheating, the cross-sectional area of the wire must be increased, and of course the gun wire will be heavier. The current 250A national standard charging gun generally uses 80mm2 cable. The charging gun is very heavy as a whole and is not easy to bend. If you want to achieve larger current charging, you can also use dual-gun charging, but this is only a stop-gap measure in specific situations. The final solution to high-current charging can only be charging with a liquid-cooled charging gun.

There are cables and water pipes inside the liquid-cooled charging gun. The cable of the 500A liquid-cooled charging gun is usually only 35mm2, and the heat is taken away by the flow of coolant in the water pipe. Because the cable is thin, the liquid-cooled charging gun is 30% to 40% lighter than a conventional charging gun. The liquid-cooled charging gun also needs to be equipped with a cooling unit, which consists of a water tank, water pump, radiator and fan. The water pump drives the coolant to circulate in the gun line, bringing the heat to the radiator, and then blowing it away by the fan, thereby achieving a larger carrying capacity than conventional naturally cooled charging guns.

2) The gun cord is lighter and the charging equipment is lightweight.

3) Less heat, fast heat dissipation, and high safety. The pile bodies of conventional charging piles and semi-liquid-cooled charging piles are air-cooled for heat dissipation. The air enters the pile body from one side, blows away the heat of the electrical components and rectifier modules, and dissipates from the pile body on the other side. The air will be mixed with dust, salt spray and water vapor and adsorbed on the surface of internal devices, resulting in poor system insulation, poor heat dissipation, low charging efficiency, and reduced equipment life. For conventional charging piles or semi-liquid cooling charging piles, heat dissipation and protection are two contradictory concepts. If the protection is good, the heat dissipation will be difficult to design, and if the heat dissipation is good, the protection will be difficult to deal with.

The fully liquid-cooled charging pile uses a liquid-cooled charging module. There are no air ducts on the front and back of the liquid-cooled module. The module relies on the coolant circulating inside the liquid-cooled plate to exchange heat with the outside world. Therefore, the power part of the charging pile can be fully enclosed to reduce heat dissipation. The radiator is external, and the heat is brought to the radiator through the coolant inside, and the external air blows away the heat on the radiator surface. The liquid-cooled charging module and electrical accessories inside the charging pile have no contact with the external environment, thus achieving IP65 protection and higher reliability.

4) The charging noise is small and the protection level is higher. Conventional charging piles and semi-liquid-cooled charging piles have built-in air-cooled charging modules. The air-cooled modules are built with multiple high-speed small fans, and the operating noise reaches more than 65db. There are also cooling fans on the charging pile body. Currently, charging piles using air-cooled modules When running at full power, the noise is basically above 70dB. It has little impact during the day but is very disturbing at night. Therefore, the loud noise at charging stations is the most complained-about problem for operators. If complained, they have to rectify the problem. However, the rectification costs are high and the effect is very limited. In the end, they have to reduce the power to reduce the noise.

The fully liquid-cooled charging pile adopts a dual-circulation heat dissipation architecture. The internal liquid-cooling module relies on a water pump to drive the coolant circulation to dissipate heat, and transfers the heat of the module to the fin radiator. The external heat dissipation is achieved by low-speed high-volume fans or air conditioners. The heat is dissipated from the device, and the noise of the fan with low speed and large air volume is much lower than that of the small fan with higher speed. Fully liquid-cooled super-charged piles can also adopt a split heat dissipation design. Similar to a split air conditioner, the heat dissipation unit is placed away from the crowd, and it can even conduct heat exchange with pools and fountains to achieve better heat dissipation and lower costs. noise.

5) Low TCO

The cost of charging equipment at charging stations must be considered from the full life cycle cost of the charging pile. The life of traditional charging piles using air-cooled charging modules generally does not exceed 5 years, but the current lease period for charging station operations is 8-10 years. This This means that the charging equipment needs to be replaced at least once during the station’s operation cycle. On the other hand, the service life of fully liquid-cooled charging piles is at least 10 years, which can cover the entire life cycle of the station. At the same time, compared with charging piles using air-cooled modules that require frequent cabinet opening, dust removal, maintenance and other operations, fully liquid-cooled charging piles only need to be flushed after dust accumulates in the external radiator, making maintenance simple.
The TCO of a fully liquid-cooled charging system is lower than that of a traditional charging system using air-cooled charging modules, and with the widespread mass application of fully liquid-cooled systems, its cost-effectiveness advantage will become more obvious.


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