High-power liquid-cooled EV charging cable
The high-power DC charging cable uses liquid cooling technology to cool down, so that the charging cable maintains a low constant temperature during the charging process, and overcomes the thermal damage to the charging gun, charging cable, and charging pile, thereby increasing the charging current. The principle is to add a liquid cooling circulation system inside the cable, and allow the cooling system and the charging system to coexist through the sealed circulation connection inside the connector. The high-power liquid-cooled DC charging cable can fully charge or quickly charge the battery of an electric vehicle in a short time to increase the cruising range, meet customer needs, improve the utilization rate of electric vehicles, and eliminate users' concerns.
Reference Standard: IEC62893.4.2-2021
|1.Conductor||Rated temperature ：-40℃～105℃|
|Material: Bare Copper||Rated Voltage ：DC 1000V|
|2.Insulation||Maximum current ：400A、500A、600A|
|Material: TPE||Maximum power ：400KW、500KW、600KW|
|3.Filler||cable outer diameter ：24mm、28mm、36mm|
|Material: PP Cord||Min ： Bending Radius: ≥6*OD|
|4.Tube||Environmental Requirements：Compliant with RoHS and REACH|
|Material:XLPO OR FEP||The temperature of the job：conductor ≤90℃；surface≤60℃|
Instead of choosing an off-the-shelf cable, contact a design expert to ensure that your cable solution meets all your expectations. Email us: email@example.com
Overview of high-power charging
In recent years, although the new energy vehicle market has developed rapidly, fewer public charging piles, low power battery cruising range, and long charging time are still key factors restricting the development of new energy vehicles. Therefore, how to increase the range of vehicles and shorten the charging time has become the consensus of the industry.
At present, the easiest way to increase the range of electric vehicles is to increase the charging power. Generally, there are two ways, one is to increase the charging current, the other is to use high-voltage charging, of course, it may eventually be a combination of the two. Under the conditions allowed by the power battery, the output voltage of the charging pile is increased to 1000V, and the charging current is increased to 600A, and the maximum power reaches 600KW.
At present, many multinational car companies have begun to plan and build super charging infrastructure. For China, my country is currently the country with the largest production and sales of new energy vehicles in the world, as well as the country with the largest number of electric vehicle users. Buses, taxis, logistics vehicles, and shared cars have an urgent need for high-power fast charging. Shortening the charging time, reducing operating costs, and improving operating efficiency directly bring about an increase in operating revenue. In addition, there are few parking spaces for electric vehicles in my country, and public slow charging piles are not effective. Therefore, users also have a certain demand for fast charging. In addition, on highways, users want to shorten the charging time, and the demand for fast charging is more urgent.
To achieve high-power charging is actually to solve three technical problems. The first is the acceptability of car batteries, that is, problems such as battery and car voltage and heat dissipation can support high-power charging. The second point is that from the perspective of charging pile companies, charging modules are the core components of DC charging piles. To develop high-power charging piles, it is necessary to do a good job of current sharing and control between the modules to make them more stable and reliable, and the integration of the charging pile system The higher the degree, the more advantageous the cost. The third is to develop a 1000V cooling cable for the charging cable. Our company is an enterprise full-time in the research and development of charging cables, supporting major domestic and foreign charging pile enterprises and car companies, and has continuously developed various forms of liquid-cooled charging cables. To adapt to different occasions
Specifically, the high-power charging cables on the market are oil-cooled and water-cooled depending on the cooling medium. Oil cooling is to design the insulating layer as an oil pipe, directly immerse the conductor part in oil, and increase the current carrying capacity through the circulation of the insulating oil. The terminal of the oil cooling gun is a specially designed circulation system, which not only ensures the circulating cooling of the liquid, but also In order to ensure the safety of insulation, it will not conduct electricity. This type of cooling cable has an excellent cooling effect and can achieve a large current carrying capacity of 600A. The other is a water-cooled cable, that is, some water pipes are added inside the cable. The cooling medium is a non-insulated liquid, which can be pure water or antifreeze. The heat generated by the cable is transferred into the liquid through the contact between the insulation and the water pipe. , And then take away the heat through the circulation of the liquid to form a cooling effect and provide a form of current-carrying capacity. Because this form is indirect cooling, the charging current may not be larger than that of oil cooling, but due to the advantages of structural design, the outer diameter of the charging cable can be made smaller, which is especially suitable for customers to use, and has a very superior experience.
At present, these two forms are being developed and used by different customers, and through the use of our company’s cables, satisfactory test results have been obtained. Combined with the improvement of the design of the charging gun and the charging pile, the realization of high-power charging at the charging end is more and more Has become a reality.
In addition, the battery industry continues to spread good news, providing us with more safe and reliable batteries that can meet high-power charging. Once the technology is stable and can be mass-produced, the final high-power charging will be realized immediately. This is not far away. Things.