Cooling cable for high-power direct-current charging and charging cooling system

Abstract

The invention relates to the technical field of cables, and particularly discloses a cooling cable for high-power direct-current charging and a charging cooling system. The cooling cable comprises a cable core and a protective structure layer, the cable core is at least provided with two DC wire cores, a wire core cooling pipe set composed of two wire core cooling pipes, and a pin cooling pipe set composed of two pin cooling pipes, the first DC wire core is installed in the first wire core cooling pipe in a clearance penetrating mode, the second DC wire core is installed in the second wire core cooling pipe in a clearance penetrating mode, and the protective structure layer is arranged between the first wire core cooling pipe and the second wire core cooling pipe. A cooling medium for heat exchange and cooling of the DC wire core is introduced into the wire core cooling pipe group, and a cooling medium for heat exchange and cooling of the charging pin is introduced into the pin cooling pipe group. According to the invention, heat dissipation of the conductive wire core in the cable is realized through a simple and compact structure, and heat dissipation of the DC charging pin is effectively considered, so that the cooling effect of the whole charging path is maximized as much as possible, and adverse effects caused by overheating of the charging path are reliably reduced.

Description

Technical Field

[0001] The present invention relates to the field of cable technology, and in particular to a cooling cable for high-power DC charging, and a charging cooling system including the cooling cable. Background Art

[0002] The technical requirement for fast charging of electric vehicles is to use high-power DC charging. However, fast charging generates a large amount of heat in the charging cables and associated equipment (including charging guns), placing high demands on the heat dissipation performance of these cables and associated equipment.

[0003] In order to achieve effective heat dissipation in charging cables for fast charging of electric vehicles, the current common technical means is to lay cooling tubes inside the cable core that can pass cooling media (such as insulating oil, compressed air, cooling water, etc.). The cooling medium flowing in the cooling tubes can then exchange heat with the heat transmitted by the electric energy and dissipate heat, which is what the industry calls a "cooling cable."

[0004] Currently, although common cooling cables have various structural forms, they only cool the conductive cores within the cable core that constitute the cable. In other words, they perform heat exchange and heat dissipation on the conductive cores that transmit electrical energy, but cannot directly perform heat exchange and heat dissipation on the remote charging gun to which the cooling cable is connected, especially the DC charging pins within the charging gun. It should be noted that in the structure of the charging gun, the main heat source is the DC charging pins. Therefore, the heat exchange and heat dissipation of common cooling cables currently available are targeted at the conductive cores that constitute the cable, and cannot effectively perform heat exchange and heat dissipation on the charging gun that is equipped with the cooling cable. As a result, the heat dissipation effect on the conductive cores is limited on the DC charging pins of the charging gun. The charging gun, which serves as a fast charging path for electric vehicles, suppresses charging efficiency and poses a safety hazard of heat generation. Summary of the Invention

[0005] The technical purpose of the present invention is to provide a high-power DC charging cooling cable and a charging cooling system that can dissipate heat from both the conductive core inside the cable and the DC charging pins inside the charging gun, in response to the particularity of the cooling cable and related equipment for fast charging of electric vehicles and the deficiencies of the existing technology.

[0006] The technical objectives of the present invention are achieved through the following technical solutions: a high-power DC charging cooling cable, comprising a cable core and a protective structure layer covering the outside of the cable core; The cable core has at least two DC cores, a core cooling tube group and a pin cooling tube group, wherein the core cooling tube group is composed of two core cooling tubes constituting a cooling circuit, and the pin cooling tube group is composed of two pin cooling tubes constituting a cooling circuit, and the pin cooling tube group is independent of the core cooling tube group; The first DC core of the two DC cores is installed in a first core cooling tube of the core cooling tube group with an annular gap fitting structure, and the second DC core is installed in a second core cooling tube with an annular gap fitting structure. The core cooling tube group is used to pass a cooling medium for heat exchange cooling of the DC cores. The pin cooling tube group is used to pass a cooling medium for heat exchange cooling of the charging pins.

[0007] Furthermore, the annular space gap matching structure installation means that when the DC core and the core cooling tube are kept coaxial, the annular space has a matching gap of at least 1 mm; The cooling medium in the core cooling tube performs heat exchange cooling on the DC core in an immersion manner.

[0008] Furthermore, the cooling medium is compressed air or insulating oil; The DC wire core is a bare wire structure.

[0009] Alternatively, the cooling medium is cooling water; The DC core has an insulation protection structure.

[0010] Furthermore, the diameters of the two pin cooling tubes of the pin cooling tube group are respectively smaller than the diameters of the core cooling tubes of the core cooling tube group; In the cable core structure, the two core cooling tubes of the core cooling tube group are arranged closely together, and the two pin cooling tubes of the pin cooling tube group are disposed at the fitting gaps on both sides of the core cooling tube group.

[0011] A charging cooling system includes a charging pile end, a charging gun end, and a charging cable electrically connected between the charging pile end and the charging gun end for transmitting electric energy; The charging gun end is provided with two DC charging pins; The charging cable is any of the above-mentioned high-power DC charging cooling cables; The cooling channel of the pin cooling tube group of the high-power DC charging cooling cable is correspondingly connected to the DC charging pins.

[0012] Furthermore, the first pin cooling tube in the pin cooling tube group is connected to the two DC charging pin drainage ends of the charging gun end through the shunt side Y-shaped tee.

[0013] Furthermore, the second cooling tube of the pin in the pin cooling tube group is connected to the discharge ends of the two DC charging pins at the charging gun end through the Y-shaped tee on the confluence side.

[0014] Furthermore, the core cooling tube group of the high-power DC charging cooling cable has a core cooling tube rotary joint arranged at the charging gun end, and the core cooling tube rotary joint connects the first core cooling tube and the second core cooling tube of the core cooling tube group at the charging gun end.

[0015] Furthermore, a compressed air machine is arranged at the end of the charging pile; The first air outlet of the compressed air machine is connected to one end of the first wire core cooling tube of the wire core cooling tube group; The second air outlet of the compressed air machine is connected to one end of the first cooling tube of the pin of the pin cooling tube group through a vortex cooling tube.

[0016] The beneficial technical effect of the present invention is: the above technical measures are aimed at the particularity of the above-mentioned cooling cable for fast charging of electric vehicles and related equipment. A core cooling tube group and a pin cooling tube group are integrated in the cable core of the cooling cable, which can not only make the cable core round but also operate independently of each other. The cooling medium in the core cooling tube group performs immersion heat exchange and heat dissipation on the DC core installed therein, and the cooling medium in the pin cooling tube group performs heat exchange and heat dissipation on the DC charging pins in the remote charging gun. Therefore, with a simple and compact structure, while achieving heat dissipation of the conductive core inside the cable, the heat dissipation of the DC charging pins in the charging gun is effectively taken into account, so that the cooling effect of the entire charging path of the electric vehicle is maximized as much as possible, and the adverse effects of overheating of the charging path on the fast charging of the electric vehicle (including charging efficiency and safety hazards) are reliably reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a schematic structural diagram of the cooling cable of the present invention.

[0018] Figure 2 This is a structural schematic diagram of the charging cooling system of the present invention.

[0019] The meaning of the codes in the figure are as follows: 1—first DC core; 2—second DC core; 3—first core cooling tube; 4—second core cooling tube; 5—core cooling tube rotary joint; 6—first cooling tube pin; 7—second cooling tube pin; 8—Y-type tee on the diversion side; 9—Y-type tee on the converging side; 10—protective structure layer; 11—compressed air machine; 12—first air outlet; 13—second air outlet; 14—vortex cooling tube; 15—DC charging pin. A—Charging pile end; B—Charging cable; C—Charging gun end. DETAILED DESCRIPTION

[0020] The present invention relates to the field of cable technology, specifically a high-power DC charging cooling cable and a charging cooling system including the cooling cable. The main technical solution of the present invention is described in detail below with reference to multiple embodiments. Figure 1 and Figure 2 The technical solution of the present invention is clearly and in detail explained; although other embodiments are not separately drawn with drawings, their main structures can still refer to the drawings of Example 1.

[0021] It should be noted that the drawings of the present invention are schematic and have been simplified to clarify the technical objectives of the present invention and to avoid obscuring the present invention's contribution to the prior art. Furthermore, expressions such as "approximately" and "substantially" regarding quantities or fitting relationships below are intended to allow for reasonable assembly and processing errors within the industry and do not literally represent absolute quantities or fitting relationships.

[0022] Example 1 See also Figure 1 As shown, the present invention is a high-power DC charging cooling cable, comprising a cable core and a protective structural layer 10 (including but not limited to a tape layer, a sheath layer, etc., as described for conventional cooling cable protective structural layers) covering the cable core. The present invention contributes to the prior art by improving the cable core's structural composition.

[0023] Specifically, the cable core of the present invention comprises at least two DC cores (i.e., a first DC core 1 and a second DC core 2), a core cooling tube assembly, and a pin cooling tube assembly (for other possible signal cores, see conventional cooling cables). The core cooling tube assembly comprises two core cooling tubes (i.e., a first core cooling tube 3 and a second core cooling tube 4) forming a cooling circuit, while the pin cooling tube assembly comprises two pin cooling tubes (i.e., a first pin cooling tube 6 and a second pin cooling tube 7) forming a cooling circuit. The pin cooling tube assembly cooperates with the core cooling tube assembly to round the cable core cross-section, but its cooling path operates essentially independently of the core cooling tube assembly.

[0024] The first core cooling tube 3 and the second core cooling tube 4 are respectively formed by extrusion of heat-resistant silicone rubber. In the cable core structure, the first core cooling tube 3 and the second core cooling tube 4 are arranged side by side.

[0025] The first and second pin cooling tubes 6 and 7 are each formed from heat-resistant silicone rubber extrusions. Their diameters are smaller than those of the core cooling tubes in the core cooling tube group (i.e., the first core cooling tube 3 and the second core cooling tube 4). Within the cable core, the first and second pin cooling tubes 6 and 7 are positioned in the gaps between the core cooling tube groups. Filler rope is used to round the cable core. The rounded cable core is then tightened and shaped with a tape layer, allowing the protective structure, including the sheath, to be overmolded around the cable core.

[0026] The two DC cores are constructed from twisted copper wires and are bare conductors without insulation. The first DC core 1 is installed within the first core cooling tube 3, while the second DC core 2 is installed within the second core cooling tube 4. This annular clearance arrangement means that when the DC cores (first DC core 1 / second DC core 2) and their respective cooling tubes (first core cooling tube 3 / second core cooling tube 4) are coaxially installed, the annulus has a clearance of approximately 1 mm, creating space for the cooling medium within the cooling tubes to immerse and cool the DC cores. While the annular clearance in this arrangement is not constant, it changes dynamically with the cable's bending during use. Regardless of this variation, the resulting clearance remains essentially constant, ensuring smooth flow of the cooling medium within the cooling tubes, allowing the cooling medium within the cooling tubes to essentially immerse and cool the DC cores. The first and second core cooling tubes 3 and 4 of the core cooling tube group are used to pass a cooling medium—preferably compressed air—through the cooling channel to cool the DC cores. The two DC cores form the positive and negative poles in the operating environment.

[0027] The first pin cooling tube 6 and the second pin cooling tube 7 that make up the pin cooling tube group are used to pass a cooling medium into the cooling channel to perform heat exchange cooling on the DC charging pins at the charging gun. The cooling medium is of the same source as the cooling medium passed into the wire core cooling tube group, that is, compressed air is preferably used.

[0028] The above is the molding structure of the cooling cable of the present invention, and the cooling cable is applied to the charging cooling system (or charging pile system) of electric vehicles.

[0029] See also Figure 2 As shown, the charging cooling system of the present invention includes a charging pile end A, a charging gun end C, and a charging cable B electrically connected between the charging pile end A and the charging gun end C for transmitting electric energy.

[0030] Among them, a compressed air machine 11 serving as a cooling air source is arranged at the charging pile end A to deliver a cooling medium serving as compressed air to the charging cable B.

[0031] Two DC charging pins 15 constituting positive and negative poles are arranged at the end C of the charging gun for charging the electric vehicle.

[0032] Charging cable B utilizes the aforementioned high-power DC charging cooling cable structure. It electrically connects the power supply at charging pile end A to the DC charging pins 15 at charging gun end C via the first DC core 1 and second DC core 2. The first core cooling tube 3 is sealed to the air outlet of the compressed air generator 11 at charging pile end A, and the first pin cooling tube 6 is sealed to the air outlet of the compressed air generator 11 at charging pile end A. To accommodate the simultaneous sealing of the first core cooling tube 3 and the first pin cooling tube 6, the air outlet of the compressed air generator 11 has two independent branches: a first outlet 12 and a second outlet 13. The first outlet 12 is sealed to the first core cooling tube 3, and the second outlet 13 is sealed to the first pin cooling tube 6. To ensure that the cooling medium transported over long distances effectively cools the DC charging pins 15 at charging gun end C, a vortex cooling tube 14 is connected to the pipeline of the second outlet 13.

[0033] The first wire core cooling tube 3 and the second wire core cooling tube 4 that constitute the wire core cooling tube group are sealed and connected at the charging gun end C by the wire core cooling tube rotary joint 5 with a U-shaped bend, so that the wire core cooling tube rotary joint 5 is sealed and connected to the first wire core cooling tube 3 and the second wire core cooling tube 4 of the wire core cooling tube group at the charging gun end C; the cooling medium entering through the first wire core cooling tube 3 flows through the wire core cooling tube rotary joint 5 and then rotates to enter the second wire core cooling tube 4, and is then discharged from the second wire core cooling tube 4 at the charging pile end A.

[0034] The first pin cooling tube 6 of the pin cooling tube assembly is sealedly connected to the drainage ends of the two DC charging pins 15 at the charging gun end C via a Y-shaped tee on the diversion side 8. Specifically, it is connected to the flow channel inlet joints of the two DC charging pins 15. The connection structure uses a hose-on-pole-type connector and is locked with a clamp. The second pin cooling tube 7 of the pin cooling tube assembly is sealedly connected to the discharge ends of the two DC charging pins 15 at the charging gun end C via a Y-shaped tee on the converging side 9. Specifically, it is connected to the flow channel outlet joints of the two DC charging pins 15. The connection structure uses a hose-on-pole-type connector and is locked with a clamp. In this way, the cooling medium entering through the first cooling tube 6 of the pin enters the two DC charging pins 15 under the diversion of the Y-shaped tee 8 on the diversion side, and cools the two DC charging pins 15 at the same temperature through heat exchange; the cooling medium flowing through the two DC charging pins 15 enters the second cooling tube 7 of the pin under the confluence of the Y-shaped tee 9 on the confluence side, and is then discharged from the second cooling tube 7 of the pin at the charging pile end A.

[0035] Example 2 The rest of this embodiment is the same as that of embodiment 1, except that: 1. The cooling medium in the wire core cooling tube group and the pin cooling tube group is insulating oil; 2. The compressed air machine at the charging pile end is replaced by an oil pump circulation system, and the two cooling tubes of the core cooling tube group form a circulation loop at the charging pile end, and the two cooling tubes of the pin cooling tube group form a circulation loop at the charging pile end.

[0036] Example 3 The rest of this embodiment is the same as that of embodiment 1, except that: 1. The cooling medium in the wire core cooling tube group and the pin cooling tube group is cooling water; 2. The compressed air machine at the charging pile end is replaced by a liquid pump circulation system, and the two cooling tubes of the core cooling tube group form a circulation loop at the charging pile end, and the two cooling tubes of the pin cooling tube group form a circulation loop at the charging pile end; 3. The DC core has an insulation protection structure to isolate the DC core conductor from the cooling water; 4. The inner walls of the two DC charging pins are provided with an insulating coating structure to isolate the DC charging pins from the cooling water from electrical conductivity.

[0037] The above embodiments are only used to illustrate the present invention, rather than to limit it.

[0038] Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the above embodiments or make equivalent replacements for some of the technical features therein; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the present invention.

Claims

1. A high-power DC charging cooling cable, comprising a cable core and a protective structure layer (10) covering the outside of the cable core; Its characteristics are: The cable core has at least two DC cores, a core cooling tube group and a pin cooling tube group, wherein the core cooling tube group is composed of two core cooling tubes constituting a cooling circuit, and the pin cooling tube group is composed of two pin cooling tubes constituting a cooling circuit, and the pin cooling tube group is independent of the core cooling tubes; The first DC core (1) of the two DC cores is installed in a first core cooling tube (3) in the core cooling tube group with an annular gap matching structure, and the second DC core (2) is installed in a second core cooling tube (4) with an annular gap matching structure. The core cooling tube group is used to pass a cooling medium for heat exchange cooling of the DC cores. The pin cooling tube group is used to pass a cooling medium for heat exchange cooling of the DC charging pin (15).

2. The high-power DC charging cooling cable according to claim 1, characterized in that: The annular space gap matching structure installation means that the DC core and the core cooling tube are kept coaxial, and the annular space has a matching gap of at least 1mm; The cooling medium in the core cooling tube performs heat exchange cooling on the DC core in an immersion manner.

3. The high-power DC charging cooling cable according to claim 1 or 2, characterized in that: The cooling medium is compressed air or insulating oil; The DC wire core is a bare wire structure.

4. The high-power DC charging cooling cable according to claim 1 or 2, characterized in that: The cooling medium is cooling water; The DC core has an insulation protection structure.

5. The high-power DC charging cooling cable according to claim 1, characterized in that: The diameters of the two pin cooling tubes of the pin cooling tube group are respectively smaller than the diameters of the wire core cooling tubes of the wire core cooling tube group; In the cable core structure, the two core cooling tubes of the core cooling tube group are arranged closely together, and the two pin cooling tubes of the pin cooling tube group are disposed at the fitting gaps on both sides of the core cooling tube group.

6. A charging cooling system, comprising a charging pile terminal A, a charging gun terminal C, and a charging cable B electrically connected between the charging pile terminal A and the charging gun terminal C for power transmission; The charging gun end C is provided with two DC charging pins (15); Its characteristics are: The charging cable B is a high-power DC charging cooling cable according to any one of claims 1 to 5; The cooling channel of the pin cooling tube group of the high-power DC charging cooling cable is correspondingly connected to the DC charging pin (15).

7. The charging cooling system according to claim 6, characterized in that: The first pin cooling tube (6) in the pin cooling tube group is connected to the drainage ends of the two DC charging pins (15) at the charging gun end C through the Y-shaped tee (8) on the shunt side.

8. The charging cooling system according to claim 6, characterized in that: The second pin cooling tube (7) in the pin cooling tube group is connected to the discharge ends of the two DC charging pins (15) at the charging gun end C through the Y-shaped tee (9) on the converging side.

9. The charging cooling system according to claim 6, characterized in that: The core cooling tube group of the high-power DC charging cooling cable has a core cooling tube rotary joint (5) arranged at the charging gun end C, and the core cooling tube rotary joint (5) connects the first core cooling tube (3) and the second core cooling tube (4) of the core cooling tube group at the charging gun end C.

10. The charging cooling system according to any one of claims 6 to 9, characterized in that: The charging pile end A is provided with a compressed air machine (11); The first air outlet (12) of the compressed air machine (11) is connected to one end of the first wire core cooling tube (3) of the wire core cooling tube group; The second air outlet (13) of the air compressor (11) is connected to one end of the first pin cooling tube (6) of the pin cooling tube group via a vortex cooling tube (14).

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