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Liquid-cooled cable

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.

The advantages of using liquid-cooled charging cables are obvious

The traditional DC charging pile adopts direct ventilation and heat dissipation, which has low protection level and poor reliability. In the early stage of market development, charging piles with IP20 direct ventilation and cooling technology are difficult to meet the application needs in harsh environments. In addition, the disadvantage of direct ventilation and heat dissipation is that the air is not isolated from the internal components of the module, and the air will be mixed with dust, salt mist and moisture and adsorbed on the surface of the internal components of the Increased risk of module failure.

Conventional direct ventilation creates a lot of noise, and residents complain that it reduces the uptime of charging stations. The air-cooled cooling module adopts a high-speed fan for strong exhaust air, coupled with the cooling fan on the pile body, the noise even exceeds 70dB, exceeding the national noise limit. Among them, the noise of charging piles is the most complained problem by operators. 

Liquid cooling technology can solve the problems of high module failure rate and loud noise at the same time. The charging module and heating element inside the system exchange heat with the radiator through the coolant, which is completely isolated from the external environment and does not come into contact with dust, flammable and explosive gases, etc. The cooling charging system is much higher than the traditional air-cooled charging system. At the same time, the liquid-cooled charging module does not have a cooling fan, and the cooling liquid is driven by a water pump to dissipate heat. The module itself has zero noise, and the system uses a fan with large air volume and low low-frequency noise.

Advantages of liquid cooling

 high protection  Traditional air-cooled charging piles are generally designed with IP54 design. In dusty construction sites, high temperature, high humidity and high salt fog, seaside and other application scenarios have a high failure rate. Liquid cooling systems can easily achieve IP65 design to meet various harsh scenarios.
 low noise  The liquid-cooled charging module can achieve zero noise, and the liquid-cooled charging system can adopt a variety of thermal management technologies, such as refrigerant heat exchange and water-cooled air-conditioning heat dissipation, with good heat dissipation effect and low noise.
 Good heat dissipation  The heat dissipation effect of the liquid-cooled module is much better than that of the traditional air-cooled module. The internal key components are about 10 degrees Celsius lower than the air-cooled module. The lower temperature energy conversion efficiency is higher, and the life of the electronic components is longer. Heat dissipation can improve the power density of the module and apply a higher power charging module.
 Easy to maintain  The traditional air-cooled charging system needs to regularly clean or replace the filter screen of the pile body, regularly dust the pile fan, remove the dust from the module fan, replace the module fan or clean the dust inside the module. Depending on different application scenarios, annual maintenance is required. 6 to 12 times, the labor cost is high, and the liquid-cooled charging system only needs to regularly detect the coolant and clean the dust on the radiator, which is greatly simplified into operation and maintenance work.
 Low TCO  At present, there are few applications of liquid-cooled charging system, so the equipment cost is higher than that of traditional air-cooled system. However, from the perspective of equipment life cycle, the whole life-cycle cost of Ling-cooled system is lower than that of air-cooled system.
 more convenient to charge  Under the same charging power, the outer diameter of the cable using liquid cooling is smaller, and the weight of the cable is reduced by 50%, making it easier and more convenient to use.
 Charge faster  Using liquid-cooled charging is more efficient. The maximum charging cable of traditional air-cooled charging piles is 200A, while using liquid-cooled charging can provide up to 600A.

Compared with air cooling, liquid cooling has better performance and higher cost. It will gradually become the mainstream trend of module cooling in the future. 

The heat dissipation capacity of the liquid cooling module is 10~20℃ lower than that of the forced air cooling module, and the intelligent noise reduction control can meet the installation and use in noise-sensitive scenarios. The liquid cooling module also has a higher IP level of protection, which is suitable for applications in harsh scenarios such as heavy dust.

The difficulty of liquid cooling heat dissipation mainly lies in the sealing of coolant and cables. 

Liquid cooling needs to set up a special circulation channel between the cable and the charging gun, add cooling liquid to the channel, and push the liquid circulation through the power pump to take out the heat to dissipate heat. However, the environment in which the charging pile is installed and used may face extreme weather, harsh environment and other factors. If the pipeline leaks due to poor cable sealing, it is easy to cause the cooling system to fail and cause accidents. Therefore, the liquid-cooled cables used need to pass the tests of high temperature resistance, corrosion resistance, blast resistance, weather resistance and low temperature resistance.

Comparison of heat dissipation performance between air cooling and liquid cooling

 Performance  Air cooling  Liquid cooled
 Heat dissipation capacity  Restricted, use more charging modules below 30KW  Compared with the forced air cooling module, the temperature is 10~20 degrees Celsius lower, and it is suitable for charging modules above 30KW.
 Noise control  Greater than or equal to 60 decibels (restricted for applications in residential areas and commercial areas)  less than or equal to 35 decibels
 Protection class  IP20  IP54
 Service life  3-5 years  more than 10 years
 Operation and maintenance  3-6 times/year  no need
 Technical Difficulties  Noise, heat dissipation performance  cable seal

OMG EV Liquid Cooled Cables:

OMG EV Cable entered the electric vehicle charging market in 2009 and entered the high-power liquid-cooled charging business with its own technical reserves. In 2019, the company developed and launched a liquid-cooled charging cable for fast charging of electric vehicles. On the premise that the standard has not been implemented globally, the cable is produced using the IEC62893.4.2 standard. At present, the company's liquid-cooled charging cable business includes water-cooled charging cables and oil-cooled charging cables.

Reference Standard: IEC62893.4.2-2021

Product description:

 Construction                                Features                                            
  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℃
 Material: TPU  

High-power water-cooled DC charging cable

What medium does the liquid-cooled charging cable use to dissipate heat?

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.

Instead of choosing an off-the-shelf cable, contact a design expert to ensure that your cable solution meets all your expectations. Email us: leo@omgevcable.com

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