Liquid-cooled intelligent charging cable and heat dissipation control method thereof

Abstract

The invention relates to a liquid-cooled intelligent charging cable and a heat dissipation control method thereof, and relates to the technical field of power transmission cables, the charging cable comprises a cable body, the cable body comprises a central conductor, the outer side of the central conductor is wrapped with an insulating layer, the outer side of the insulating layer is wrapped with an outer sheath layer, and the outer sheath layer and the insulating layer are arranged at an interval to form a liquid-cooled cavity; the liquid cooling mechanism comprises a liquid cooling circulation assembly and a plurality of spiral heat exchange pipes, the spiral heat exchange pipes are located in the liquid cooling cavity, the multiple spiral heat exchange pipes are sequentially arranged in the length direction of the cable body, and the spiral heat exchange pipes communicate with the liquid cooling circulation assembly; the temperature control mechanism comprises a controller and a plurality of temperature sensors, the temperature sensors are arranged on the insulating layer, the temperature sensors are sequentially arranged in the length direction of the cable body, and the temperature sensors and the liquid cooling circulation assembly are electrically connected with the controller. The continuous high-power current-carrying capability of the cable can be improved.

Description

Technical Field

[0001] This application relates to the technical field of power transmission cables, and in particular to a liquid-cooled intelligent charging cable and its heat dissipation control method. Background Technology

[0002] With the development of electric vehicle technology, users' demand for charging speed is becoming increasingly urgent. High-power DC fast charging has become a key technology in the industry. When charging at high power, the current in the charging cable will remain at a high level. According to Joule's law, the charging current will generate a huge amount of Joule heat. If this heat cannot be dissipated in time, it will cause the cable temperature to rise rapidly, which will seriously affect the service life of the cable and even cause fire safety problems.

[0003] To improve the heat dissipation performance of cables, existing charging cables mainly adopt the following technical solutions: natural convection heat dissipation: relying on the cable outer sheath to exchange heat naturally with the surrounding air; forced air cooling heat dissipation: setting up ventilation channels inside the cable and equipping it with fans to force airflow to remove heat; phase change material heat dissipation: filling the cable sheath layer with phase change materials (PCM) such as paraffin wax, and using the material phase change process to absorb a large amount of heat.

[0004] Regarding the aforementioned technologies, the increasing demands on cable charging capabilities necessitate cables capable of continuous high-power charging. However, among the various heat dissipation solutions, natural convection cooling has extremely low efficiency, with heat accumulation far exceeding dissipation. Forced air cooling offers some improvement, but its capacity is limited by air's low specific heat capacity, and the system is large and complex. Phase change materials, due to their limited heat capacity, rapidly reach thermal saturation and fail during continuous charging. Therefore, existing cable heat dissipation solutions suffer from overall limitations, failing to meet the demands of continuous high-power charging. This makes the cables highly susceptible to localized overheating, triggering the charging station's power derating protection and severely impacting charging efficiency and user experience. Summary of the Invention

[0005] This application provides a liquid-cooled intelligent charging cable and its heat dissipation control method. The purpose is to enhance the heat dissipation capacity of the cable, prevent local overheating of the cable during actual operation and trigger the power derating protection of the charging pile, and enable the cable to have the ability to continuously charge at high power.

[0006] Firstly, the liquid-cooled smart charging cable provided in this application adopts the following technical solution: A liquid-cooled smart charging cable includes a cable body, a central conductor, an insulation layer wrapped around the central conductor, an outer sheath layer wrapped around the insulation layer, and the outer sheath layer and the insulation layer being spaced apart to form a liquid-cooled cavity; a liquid-cooling mechanism, including a liquid-cooling circulation assembly and a plurality of spiral heat exchange tubes, the spiral heat exchange tubes being located within the liquid-cooled cavity, the plurality of spiral heat exchange tubes being arranged sequentially along the length of the cable body, the spiral heat exchange tubes being connected to the liquid-cooling circulation assembly, the liquid-cooling circulation assembly being used to drive the coolant to circulate within the spiral heat exchange tubes and to control the flow rate of the coolant circulating within each spiral heat exchange tube; and a temperature control mechanism, including a controller and a plurality of temperature sensors, the temperature sensors being disposed on the insulation layer, the plurality of temperature sensors being arranged sequentially along the length of the cable body, the temperature sensors and the liquid-cooling circulation assembly being electrically connected to the controller.

[0007] By adopting the above technical solution, a liquid cooling mechanism is set on the basis of the cable body. The liquid cooling mechanism, through the cooperation of the spiral heat exchange tube and the liquid cooling circulation component, can realize the heat dissipation function of the cable body by circulating coolant into the spiral heat exchange tube.

[0008] Based on this, the cable body is divided into several cooling sections along its length, and each cooling section is equipped with a spiral heat exchange tube and a temperature sensor. The liquid cooling circulation assembly and the temperature sensor are all electrically connected to the controller. This partitioned design allows the controller to acquire real-time temperature data for all cooling sections of the cable body through several temperature sensors. Based on this temperature data, the controller independently controls the liquid cooling circulation assembly to adjust the coolant flow rate in the corresponding spiral heat exchange tube, thus enabling independent adjustment of the heat dissipation efficiency of each cooling section.

[0009] Therefore, by independently controlling the heat dissipation efficiency of each cooling section, the problem of localized overheating caused by uneven heat dissipation or untimely response in the cable can be solved. Specifically, when the temperature of a certain cooling section rises abnormally, the controller can actively enhance the heat dissipation efficiency of that cooling section. This maximizes the cable's continuous current-carrying capacity while ensuring safety, thereby significantly improving the charging efficiency of the cable in this application.

[0010] Optionally, the spiral heat exchange tube is spirally wound around the outside of the insulation layer.

[0011] By adopting the above technical solution, the spiral heat exchange pipe is spirally wound on the outside of the insulation layer, so that the spiral heat exchange pipe can fit tightly against the surface of the insulation layer. This can increase the actual laying length and effective heat exchange area of ​​the spiral heat exchange pipe within the limited straight length of the cable body, thereby improving the heat dissipation efficiency per unit length of cable.

[0012] Optionally, the outer wall of the insulating layer is provided with a spiral groove, and the spiral heat exchange tube is embedded in the spiral groove.

[0013] By adopting the above technical solution, the spiral groove structure on the outer side of the insulation layer provides positioning and stable mechanical fixation for the spiral heat exchange tube, preventing it from shifting during use. Simultaneously, this design also ensures a surface-to-surface fit between the spiral heat exchange tube and the insulation layer, eliminating air gaps between them to reduce interfacial thermal resistance and further improve heat transfer efficiency.

[0014] Optionally, the spiral heat exchange tube includes an outer tube, inside which a water inlet pipe and a water outlet pipe are provided. The length directions of the water inlet pipe and the water outlet pipe are both along the length direction of the outer tube. One end of the outer tube extends out of the outer sheath layer. The outer tube is connected to the liquid cooling circulation assembly. The water inlet pipe and the water outlet pipe are both connected to the liquid cooling circulation assembly. The ends of the water inlet pipe and the water outlet pipe away from the liquid cooling circulation assembly are connected to each other.

[0015] By adopting the above technical solution, based on the structural design of the spiral heat exchanger tube, a complete U-shaped zigzag flow path is constructed inside the outer tube through the cooperation of the inlet and outlet pipes. This allows the coolant to be injected into and out of the spiral heat exchanger tube from one end. This design, on the one hand, allows the coolant to circulate by connecting only one end of the spiral heat exchanger tube to the liquid cooling circulation assembly, thus simplifying pipe connections and reducing the complexity of the entire piping system. On the other hand, it extends the flow path of the coolant within the spiral heat exchanger tube, thereby improving the heat exchange efficiency of the coolant.

[0016] Optionally, the inlet pipe is located on the side of the outlet pipe closest to the insulating layer.

[0017] By adopting the above technical solution, the design of the inlet and outlet pipes ensures that the inlet pipe, which transports the low-temperature coolant, is positioned closest to the heat source, achieving the most efficient heat exchange and absorbing core heat immediately. Furthermore, placing the outlet pipe, which transports the heated coolant, outside the inlet pipe reduces heat exchange between the already heated coolant in the outlet pipe and the low-temperature coolant in the inlet pipe. This improves the heat exchange efficiency of the low-temperature coolant in the inlet pipe to the heat source, thereby enhancing heat dissipation efficiency.

[0018] Optionally, a heat-conducting layer is provided on the outside of the water inlet pipe, and a heat-insulating layer is provided on the outside of the water outlet pipe.

[0019] By adopting the above technical solution, the heat-conducting layer enhances the ability of the inlet pipe to absorb heat from the heat source; while the heat insulation layer actively prevents the already heated coolant in the outlet pipe from leaking heat back to the inlet pipe. This effectively avoids thermal short circuits in the cooling flow path inside the outer pipe, thereby improving the overall heat exchange efficiency of the spiral heat exchanger tube.

[0020] Optionally, the outer tube is filled with a heat-conducting medium layer, which encloses the inlet pipe and the outlet pipe.

[0021] By adopting the above technical solution, the heat-conducting medium layer fills all the gaps between the inlet pipe, the outlet pipe and the outer pipe. This allows the heat-conducting medium layer to act as a bridge for heat transfer, conducting the heat transferred from the insulation layer to the surface of the inlet pipe, where it is then absorbed by the low-temperature coolant inside the inlet pipe. This ensures that the heat generated by the heat source is fully absorbed, further reducing the total thermal resistance and enhancing the heat exchange effect.

[0022] Optionally, one end of the outer tube is provided with a first collection interface, and the other end is provided with a second collection interface. The two ends of the inlet pipe are respectively connected to the corresponding first collection interface and the corresponding second collection interface, and the two ends of the outlet pipe are respectively connected to the corresponding first collection interface and the corresponding second collection interface. The first collection interface is located outside the outer sheath layer, and the first collection interface is plugged into and connected to the liquid cooling circulation component. A return flow component is plugged into the second collection interface, and the inlet pipe, the return flow component, and the outlet pipe are connected in sequence.

[0023] By adopting the above technical solution, based on the coordinated design of the first and second manifold interfaces and the return component on the outer tube, the return component short-circuits the inlet and outlet pipes at the second manifold interface, forming a reversible path. Meanwhile, the first manifold interface gathers the inlet and outlet coolant from the spiral heat exchanger tube to one end of the spiral heat exchanger tube. Therefore, after the first manifold interface is plugged into the corresponding liquid cooling circulation component, a connection between the spiral heat exchanger tube and the liquid cooling circulation component can be quickly established. This design simplifies on-site installation, plugging / unplugging, and maintenance operations, and improves the reliability and ease of use of the cable.

[0024] Optionally, both ends of the outer tube extend beyond the outer sheath layer along its length, and both the first collection interface and the second collection interface are located outside the outer sheath layer.

[0025] By adopting the above technical solution, since both ends of the outer tube extend with an outer sheath, the first and second assembly ports on the outer tube, used for connection, are exposed outside the cable body. This design reduces the possibility of leakage in the spiral heat exchanger pipe, thus facilitating its installation and maintenance. Furthermore, it allows the spiral heat exchanger pipe to function as an independent unit, making it easier to install within the cable body. This also facilitates the connection, installation, production, and replacement of the spiral heat exchanger pipe.

[0026] Secondly, the heat dissipation control method for a liquid-cooled intelligent charging cable provided in this application adopts the following technical solution: A heat dissipation control method for a liquid-cooled intelligent charging cable, used to control a liquid-cooled intelligent charging cable, further includes the following steps: several temperature sensors acquire temperature data of various sections on the cable body in real time, and transmit the temperature data to a controller; the controller compares the acquired temperature data with a preset high-temperature limit to determine whether the temperature of the corresponding section of the cable body exceeds the preset high-temperature limit; when the temperature of the corresponding section of the cable body exceeds the preset high-temperature limit, the controller controls the liquid cooling circulation component to increase the flow rate of the coolant in the corresponding spiral heat exchange tube, thereby reducing the temperature of the corresponding section of the cable body.

[0027] By adopting the above technical solution, this method establishes a dynamic adjustment mechanism based on real-time temperature feedback. By detecting temperature data, determining whether the temperature data exceeds the preset high temperature limit, and performing a cycle of cooling efficiency regulation, the limited coolant is dynamically and preferentially allocated to the local hot spots that need cooling the most. This ensures that the temperature of the entire cable is always within a safe and controllable range, thereby maximizing the ultimate current carrying capacity of the entire cable and achieving the highest charging efficiency under safe conditions.

[0028] In summary, this application includes at least one of the following beneficial technical effects: 1. This application utilizes a combination of spiral heat exchange tubes in the liquid cooling mechanism and temperature sensors in the temperature control mechanism to partition the cable body into zones. These zones are then uniformly controlled by a controller, enabling intelligent thermal management that allows for real-time monitoring and dynamic adjustment of the cable body in zones as needed. This proactively suppresses the formation of local hot spots on the cable, thus solving the problem of local overheating caused by uneven heat dissipation or untimely response in existing technologies. This improves the cable's continuous high-power current carrying capacity and charging efficiency.

[0029] 2. This application achieves a highly efficient, low-resistance, and directional heat transfer channel from the heat source to the coolant through the structural design of the insulation layer and the internal structure of the spiral heat exchange tube, optimizes the heat exchange efficiency, avoids thermal short circuits inside the cooling flow path, and thus enhances the heat dissipation efficiency of the spiral heat exchange tube.

[0030] 3. This application utilizes the internal structure design of the spiral heat exchanger tubes, enabling each individual spiral heat exchanger tube to function as a complete cooling circulation path. This cooling circulation path can be plugged into the liquid cooling circulation assembly at one end, thereby simplifying the piping layout of the entire cable and improving the convenience, sealing, and reliability of pipe connections. With this design, several spiral heat exchanger tubes operate in parallel, ensuring stable, leak-free, and efficient circulation of the coolant throughout the entire heat dissipation section of the cable. This guarantees continuous high-efficiency heat exchange supported by enhanced heat exchange structures such as the heat-conducting layer, insulation layer, and heat-conducting medium layer, thus strengthening the overall heat dissipation performance and long-term operational reliability of the entire liquid cooling system. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the principle structure of the liquid-cooled smart charging cable of Embodiment 1 of this application.

[0032] Figure 2 This is a cross-sectional structural diagram of the cable body according to Embodiment 1 of this application.

[0033] Figure 3 This is a schematic diagram of the internal structure of the cable body according to Embodiment 1 of this application.

[0034] Figure 4 This is a schematic diagram of the overall structure of the spiral heat exchanger tube in Embodiment 1 of this application.

[0035] Figure 5 This is a schematic diagram of the overall structure of the spiral heat exchanger tube in Embodiment 2 of this application.

[0036] Figure 6 This is a cross-sectional view of the spiral heat exchanger tube of Embodiment 2 of this application.

[0037] Figure 7 This is a cross-sectional view of the first set of interfaces and quick-connect plugs in Embodiment 2 of this application.

[0038] Figure 8 This is a cross-sectional view of the second set interface and return component in Embodiment 2 of this application. In the diagram, 1. Cable body; 11. Center conductor; 12. Insulation layer; 121. Spiral groove; 122. Elastic ring; 13. Outer sheath layer; 14. Liquid cooling cavity; 15. Binding strap; 2. Liquid cooling mechanism; 21. Spiral heat exchange tube; 211. Spiral section; 212. Extension section; 213. Outer tube; 2131. First collection interface; 2132. Second collection interface; 214. Water inlet pipe; 2141. First water inlet interface; 2142. First water outlet interface; 215. Water outlet pipe; 2151. Second water inlet interface; 2152. Second water outlet. Interface; 216, Thermal conductive medium layer; 217, Return component; 2171, Return socket; 2172, Return plug; 2173, Return short pipe; 22, Liquid cooling circulation assembly; 221, Micro pump; 222, Coolant tank; 223, Supply line; 2231, Main supply pipe; 2232, Main return pipe; 2233, First pipe; 2234, Second pipe; 224, Flow control valve; 225, Quick connector; 2251, Liquid cooling socket; 2252, Quick plug; 3, Temperature control mechanism; 31, Temperature sensor; 32, Controller. Detailed Implementation

[0039] The following is in conjunction with the appendix Figure 1 -Appendix Figure 8 This application will be described in further detail below.

[0040] Example 1: A liquid-cooled smart charging cable, referring to... Figure 1 and Figure 2 The system includes a cable body 1, a liquid cooling mechanism 2, and a temperature control mechanism 3. The cable body 1 includes a central conductor 11, an insulation layer 12 wrapped around the central conductor 11, and an outer sheath layer 13 wrapped around the insulation layer 12. The outer sheath layer 13 and the insulation layer 12 are spaced apart to form a liquid cooling cavity 14. The liquid cooling mechanism 2 includes a liquid cooling circulation assembly 22 and several spiral heat exchange tubes 21. The spiral heat exchange tubes 21 are located inside the liquid cooling cavity 14 and are arranged sequentially along the length of the cable body 1. The spiral heat exchange tubes 21 are connected to the liquid cooling circulation assembly 22. The temperature control mechanism 3 includes a controller 32 and several temperature sensors 31. The temperature sensors 31 are disposed on the insulation layer 12 and are arranged sequentially at intervals along the length of the cable body 1. The temperature sensors 31 and the liquid cooling circulation assembly 22 are both electrically connected to the controller 32.

[0041] Based on the coordinated arrangement of the cable body 1, the liquid cooling mechanism 2, and the temperature control mechanism 3, the cable body 1 is divided into several independent cooling sections along its length. Each cooling section is equipped with a spiral heat exchange tube 21 and at least one temperature sensor 31. The temperature sensor 31 enables real-time temperature monitoring of the corresponding cooling section, and the controller 32 can independently and dynamically adjust the flow rate of the coolant in the spiral heat exchange tube 21 within the corresponding cooling section based on the monitoring results. Therefore, with this design, the cable body 1 can be zoned for real-time temperature monitoring and temperature control, which enables precise control of cooling efficiency. This allows the cooling capacity to be concentrated on the hottest areas of the cable body 1, rather than indiscriminately cooling the cable body 1. This improves the suppression of local hot spots in the cable body 1 and also enhances the temperature uniformity of the entire cable body.

[0042] Reference Figure 2 The central conductor 11 comprises several independently arranged wires, each with its own independent insulating sheath, and all wires are located within the insulating layer 12. Preferably, the wires are made of oxygen-free copper to ensure high conductivity of the central conductor 11.

[0043] Reference Figure 2 and Figure 3 A spiral groove 121 is formed on the outer wall of the insulation layer 12, and the spiral heat exchange tube 21 is embedded in the spiral groove 121. An elastic ring 122 is coaxially sleeved on the outer side of the insulation layer 12. The elastic ring 122 is located inside the outer sheath layer 13. The spiral heat exchange tube 21 is located between the elastic ring 122 and the insulation layer 12. Several elastic rings 122 are provided, and the several elastic rings 122 are arranged sequentially at intervals along the length direction of the cable body 1.

[0044] The spiral groove 121 allows the outer wall of the insulation layer 12 to fit with the spiral heat exchange tube 21, thereby increasing the contact area between the insulation layer 12 and the spiral heat exchange tube 21. This reduces the interfacial thermal resistance and improves heat exchange efficiency. The elastic ring 122 applies a continuous radial pressure to the spiral heat exchange tube 21, stably pressing it against the bottom of the spiral groove 121. This ensures a long-lasting and excellent thermal contact between the spiral heat exchange tube 21 and the insulation layer 12, preventing a decrease in heat dissipation performance due to gaps.

[0045] Reference Figure 2 In this embodiment, the insulating layer 12 is preferably made of cross-linked polyethylene. The outer sheath layer 13 is preferably made of thermoplastic polyurethane or thermoplastic elastomer, which gives the outer sheath layer 13 the characteristics of wear resistance, oil resistance and high flexibility.

[0046] Reference Figure 3 and Figure 4The spiral heat exchange tube 21 is spirally wound around the outside of the insulation layer 12, and the outer sheath layer 13 is sleeved on the outside of the spiral heat exchange tube 21. Both ends of the spiral heat exchange tube 21 extend out of the outer sheath layer 13 and are connected to the liquid cooling circulation assembly 22.

[0047] Reference Figure 3 and Figure 4 In this embodiment, the spiral heat exchange tube 21 includes a spiral section 211, and extension sections 212 are provided at both ends of the spiral section 211. The spiral section 211 is embedded in the spiral groove 121 on the outside of the insulation layer 12. Both extension sections 212 extend out of the outer sheath layer 13, and the extension sections 212 extend along the length direction of the cable body 1 to the end of the cable body 1. Therefore, at the end of the cable body 1, the extension section 212 is connected to the liquid cooling circulation assembly 22.

[0048] Reference Figure 2 and Figure 3 In this embodiment, a binding strap 15 is wrapped around the outside of the cable body 1. The binding strap 15 binds the extension section 212 outside the cable body 1 to the cable body 1, so that the extension sections 212 of all spiral heat exchange tubes 21 are located between the binding strap 15 and the outer sheath layer 13. With this design, the external structure of the cable body 1 is more compact and neat, which is convenient for users to drag and use. Moreover, the extension section 212 of the spiral heat exchanger extends along the length direction of the cable body 1, so the coolant passing through the extension section 212 can further dissipate heat or insulate the cable body 1.

[0049] Reference Figure 1 and Figure 4 In this embodiment, the liquid cooling circulation assembly 22 includes a micro pump 221, a coolant storage tank 222, a liquid supply pipeline 223, and several flow control valves 224. The liquid supply pipeline 223 includes a main liquid supply pipe 2231 and a main liquid return pipe 2232, both of which are connected to the coolant storage tank 222. The micro pump 221 is mounted on the main liquid supply pipe 2231, which is connected to several first pipes 2233. Each first pipe 2233 corresponds to a spiral heat exchange tube 21, with one end of each first pipe 2233 connected to the main liquid supply pipe 2231 and the other end connected to an extension section 212 on the corresponding spiral heat exchange tube 21. A number of second pipes 2234 are connected to the main return pipe 2232. Each second pipe 2234 is configured to correspond one-to-one with a spiral heat exchanger tube 21. One end of each second pipe 2234 is connected to the main return pipe 2232, and the other end is connected to another extension 212 on the corresponding spiral heat exchanger tube 21. Each first pipe 2233 is configured to correspond one-to-one with a flow control valve 224, which is installed on the corresponding first pipe 2233.

[0050] Specifically, the micro pump 221 is a brushless DC diaphragm pump, which has the advantages of stable operation, long service life, and flow rate that can be precisely adjusted by the controller 32; the coolant storage tank 222 is a sealed container made of corrosion-resistant polypropylene material and is equipped with a liquid level sensor; the flow control valve 224 is an electronically controlled proportional solenoid valve, which can realize linear stepless adjustment of the corresponding opening degree according to the analog signal or PWM signal output by the controller 32.

[0051] Reference Figure 1 In this embodiment, in order to ensure that the temperature of the coolant in the coolant storage tank 222 can be reduced quickly, a radiator is provided on the coolant storage tank 222. The radiator can be a cooling fan or a liquid-cooled heat sink with cooling fins, and the heat in the coolant can be dissipated to the environment through forced air cooling or secondary liquid cooling circulation.

[0052] Reference Figure 1 In the design of the liquid cooling circulation component 22, several spiral heat exchange tubes 21 are connected in parallel, and the flow rate of each spiral heat exchange tube 21 is adjustable, thus forming a parallel coolant circulation system in which the flow rate of each branch can be independently controlled. Among them, the controller 32 can dynamically and on demand distribute the total coolant flow rate among the cooling sections by adjusting the opening of each flow control valve 224, thereby realizing intelligent control.

[0053] Reference Figure 1 and Figure 4 In this embodiment, the spiral heat exchanger tube 21 is made of stainless steel corrugated pipe. Based on the corrugated inner wall structure of the stainless steel corrugated pipe, the corrugated inner wall structure induces turbulence in the coolant as it flows inside, thereby improving the heat exchange effect. At the same time, this also gives the spiral heat exchanger tube 21 good flexibility, thus meeting the requirements of the spiral heat exchanger tube 21 being wound around the insulation layer 12 and the bending requirements of the cable during use.

[0054] Theoretically, when one end of the spiral heat exchange tube 21 is connected to the liquid cooling circulation assembly 22, liquid energy dissipation can also be achieved. For example, the liquid cooling circulation assembly 22 can input coolant into the spiral heat exchange tube 21 and then extract the coolant, repeating the entire process to achieve the recycling of the coolant. However, in practice, this embodiment adopts a design where both ends of the spiral heat exchange tube 21 extend outwards with outer sheath layers 13 in order to maximize reliability and simplify the manufacturing process.

[0055] Reference Figure 1The temperature control mechanism 3 includes a controller 32 and several temperature sensors 31. The temperature sensors 31 are embedded within or attached to the outer wall of the insulation layer 12. At least one temperature sensor 31 is correspondingly installed in each cooling section of the cable body 1. The temperature sensors 31 and the liquid cooling circulation assembly 22 are all electrically connected to the controller 32. Specifically, the micro pump 221, the coolant storage tank 222, and several flow control valves 224 in the liquid cooling circulation assembly 22 are all electrically connected to the controller 32.

[0056] In this embodiment, the temperature sensor 31 is a surface-mount NTC thermistor. Its installation method is as follows: during manufacturing, the temperature sensor 31 is attached to the outer wall of the insulating layer 12, thereby enabling it to sense heat changes in the cooling section. The signal leads of the temperature sensor 31 are integrated into a dedicated signal cable with an electromagnetic shielding layer. This signal cable is located inside the outer sheath layer 13 and extends to the end of the cable body 1, extending from within the outer sheath layer 13 to connect to the controller 32, ensuring the accuracy of temperature signal transmission in a strong electromagnetic environment.

[0057] Reference Figure 1 and Figure 3 Specifically, the temperature sensor 31 is preferably installed at the bottom of the spiral groove 121, so that the side of the temperature sensor 31 away from the insulation layer 12 is the spiral heat exchange tube 21.

[0058] With the temperature control mechanism 3 in place, the controller 32 can form a closed-loop feedback control system that can independently control the temperature of all cooling sections on the circuit body. The controller 32 can actively predict and suppress the formation of any local hot spot through the temperature sensor 31, ensuring that the temperature of any point on the cable body 1 will not exceed the safety threshold, thereby providing a safety guarantee for maintaining a higher charging current.

[0059] The implementation principle of this application embodiment is as follows: During the charging process, the controller 32 acquires the temperature data of each cooling section on the cable body 1 in real time through various temperature sensors 31. The controller 32 compares the acquired temperature data with the preset high temperature limit. When the controller 32 determines that the temperature of a cooling section exceeds the preset high temperature limit, the controller 32 sends a command to the flow control valve 224 corresponding to that cooling section to increase its opening, so that more coolant is guided into the spiral heat exchange tube 21 in that cooling section for enhanced heat dissipation. When the temperature of that cooling section is effectively controlled and falls back to a safe range, the controller 32 can maintain or appropriately reduce the opening of the corresponding flow control valve 224. Through this closed-loop control method of zoned monitoring and on-demand allocation, this application can effectively suppress the generation of local hot spots, thereby avoiding passive derating of the entire cable due to local overheating and ensuring the stable operation of continuous high-power charging.

[0060] This embodiment also discloses a heat dissipation control method for a liquid-cooled smart charging cable, including the following steps: several temperature sensors 31 acquire temperature data of each section on the cable body 1 in real time, and transmit the temperature data to the controller 32. The controller 32 compares the acquired temperature data with the preset high temperature limit to determine whether the temperature of the corresponding section of the cable body 1 exceeds the preset high temperature limit. When the temperature of the cable body 1 exceeds the preset high temperature limit, the controller 32 controls the liquid cooling circulation component 22 to increase the flow rate of the coolant in the corresponding spiral heat exchange tube 21, thereby reducing the temperature of the corresponding section of the cable body 1 until the temperature of the corresponding section of the cable body 1 is lower than the preset low temperature limit.

[0061] Specifically, in this embodiment, the controller 32 controls the flow rate of the coolant by controlling the micro pump 221.

[0062] Repeat the above steps while charging with the cable until charging is complete.

[0063] The implementation principle of this application embodiment is as follows: a dynamic adjustment mechanism based on real-time temperature feedback is established. The control method of this application abandons the passive and fixed heat dissipation mode in the existing heat dissipation scheme and instead adopts an active and variable thermal management strategy. Through continuous detection, judgment and execution steps, the limited coolant is dynamically and preferentially allocated to the local hot spots that need cooling the most, ensuring that the temperature of the entire cable is always within a safe and controllable range, thereby maximizing the ultimate current carrying capacity of the entire cable and achieving the highest charging efficiency under the premise of safety.

[0064] Example 2: A liquid-cooled smart charging cable, referring to... Figure 5 and Figure 6 The difference between this embodiment and Embodiment 1 is that the spiral heat exchanger tube 21 includes an outer tube 213, an inlet tube 214, and an outlet tube 215. The outer tube 213 is spiral-shaped along its length and is embedded in the spiral groove 121 on the outer wall of the insulating layer 12. The inlet tube 214 and the outlet tube 215 are disposed inside the outer tube 213, and the length directions of both the inlet tube 214 and the outlet tube 215 are along the length direction of the outer tube 213. The inlet tube 214 is covered with a heat-conducting layer, and the outlet tube 215 is covered with a heat-insulating layer. The inlet tube 214 is located on the side of the outlet tube 215 closest to the insulating layer 12, and the inlet tube 214 and the outlet tube 215 are spaced apart. A heat-conducting medium layer 216 is filled inside the outer tube 213, and the heat-conducting medium layer 216 surrounds the inlet tube 214 and the outlet tube 215.

[0065] Based on the structural design of the spiral heat exchanger tube 21, the arrangement of the inlet pipe 214 and outlet pipe 215 ensures that the inlet pipe 214, which transports the cryogenic coolant, is closer to the central conductor 11. This guarantees that the cryogenic coolant flowing through the inlet pipe 214 can fully absorb the heat generated by the central conductor 11. A heat-conducting layer is installed outside the inlet pipe 214, and a heat-insulating layer is installed outside the outlet pipe 215. The heat-conducting layer enhances the heat absorption capacity of the inlet pipe 214, while the heat-insulating layer actively prevents the high-temperature cooling water in the outlet pipe 215 from leaking heat back to the heat-conducting medium layer 216. Therefore, the synergistic effect of these two asymmetric designs promotes the directional transfer of heat from the central conductor 11 to the cryogenic coolant flowing through the inlet pipe 214, while suppressing internal short-circuiting of heat between the inlet pipe 214 and the outlet pipe 215, thereby improving heat exchange efficiency.

[0066] In this embodiment, the thermally conductive layer is preferably a high thermal conductivity interface material, such as a graphene thermally conductive coating or an aluminum-based / copper-based thermally conductive tape, to enhance its ability to absorb heat from the thermally conductive medium layer 216. The thermal insulation layer is preferably a flexible thermal insulation material, such as aerogel felt or aluminum silicate fiber felt, to prevent heat from being transferred backward within the water outlet pipe 215. The thermally conductive medium layer 216 is preferably a thermally conductive potting compound, such as an epoxy resin-based or silicone-based thermally conductive adhesive.

[0067] Reference Figure 5 One end of the outer tube 213 is provided with a first collection interface 2131, and the other end is provided with a second collection interface 2132. Both the first collection interface 2131 and the second collection interface 2132 enclose the outer tube 213.

[0068] Reference Figure 3 and Figure 5 Specifically, in this embodiment, the first collection interface 2131 and the second collection interface 2132 are located at the ends of the two extension sections 212 on the spiral heat exchange tube 21, respectively. The second collection interface 2132 is disposed between the outer sheath layer 13 and the binding strap 15, while the first collection interface 2131 extends to the end of the cable body 1. At the end of the cable body 1, the first collection interface 2131 extends out from between the binding strap 15 and the outer sheath layer 13.

[0069] Reference Figure 7 and Figure 8The inlet pipe 214 has a first inlet port 2141 at one end along its length toward the first collection port 2131, and a first outlet port 2142 at the other end. The outlet pipe 215 has a second outlet port 2152 at one end along its length toward the first collection port 2131, and a second inlet port 2151 at the other end. The first inlet port 2141 and the second outlet port 2152 are both fixed inside the first collection port 2131, and the first outlet port 2142 and the second inlet port 2151 are both fixed inside the second collection port 2132.

[0070] Reference Figure 5 and Figure 7 The other end of the outer tube 213 is equipped with a quick-connect fitting 225. Both the first tube 2233 and the second tube 2234 are connected to their corresponding quick-connect fittings 225. The quick-connect fittings 225 are also plugged into the first manifold interface 2131. The first tube 2233 is connected to the corresponding first water inlet interface 2141, and the second tube 2234 is connected to the corresponding second water outlet interface 2152. This quick-connect fitting design allows for rapid and modular connection between the spiral heat exchange tube 21 and the external liquid cooling circulation assembly 22. When installing or replacing cables, operators do not need to perform complex pipe connections; they only need to align and insert the quick-connect fitting 225 into the first manifold interface 2131 to complete the connection of all fluid circuits, thereby improving the convenience of on-site construction and subsequent maintenance. Reference Figure 7 In this embodiment, the quick connector 225 includes a liquid-cooled socket 2251. The liquid-cooled socket 2251 is configured one-to-one with the first tube 2233 and the second tube 2234. The first tube 2233 and the second tube 2234 are connected to the corresponding liquid-cooled socket 2251. The liquid-cooled socket 2251 is provided with two quick plugs 2252. The two quick plugs 2252 are axially arranged along the axial direction of the liquid-cooled socket 2251, and the two quick plugs 2252 are respectively connected to the first tube 2233 and the second tube 2234.

[0071] The liquid-cooled socket 2251 is configured to correspond one-to-one with the first collection interface 2131, and the liquid-cooled socket 2251 is plugged into the corresponding first collection interface 2131. When the liquid-cooled socket 2251 is plugged into the corresponding first collection interface 2131, the two quick plugs 2252 are respectively positioned opposite the first water inlet interface 2141 and the second water outlet interface 2152. After the liquid-cooled socket 2251 is plugged into the corresponding first collection interface 2131, both the first water inlet interface 2141 and the second water outlet interface 2152 are coaxially plugged into and connected to the corresponding quick plugs 2252.

[0072] Reference Figure 5 and Figure 8One end of the outer tube 213 is provided with a return flow component 217, which is inserted into the second collection interface 2132. The second water inlet interface 2151, the return flow component 217, and the first water outlet interface 2142 are connected in sequence. Under the action of the return flow component 217, the water inlet pipe 214 and the water outlet pipe 215 inside the spiral heat exchange tube 21 are connected, so that the low-temperature coolant entering through the water inlet pipe 214 will return from the water outlet pipe 215 after absorbing heat.

[0073] Reference Figure 8 In this embodiment, the return component 217 includes a return socket 2171, and two return plugs 2172 are provided on one axial side of the return socket 2171. The return plugs 2172 are axially arranged along the axial direction of the return socket 2171. A return short tube 2173 is provided on the return socket 2171, and both ends of the return short tube 2173 are respectively connected to the two return plugs 2172.

[0074] The return socket 2171 and the second collection interface 2132 are configured in a one-to-one correspondence, and the return socket 2171 is plugged into the corresponding second collection interface 2132. When the return socket 2171 is plugged into the corresponding second collection interface 2132, the two return plugs 2172 are respectively positioned opposite the second water inlet interface 2151 and the first water outlet interface 2142. After the return socket 2171 and the corresponding second collection interface 2132 are plugged into place, the second water inlet interface 2151 and the first water outlet interface 2142 are both coaxially plugged into and connected to the corresponding return plug 2172.

[0075] Reference Figure 7 and Figure 8 In this embodiment, the return plug 2172, quick plug 2252, first water inlet 2141, second water inlet 2151, first water outlet 2142, and second water outlet 2152 all adopt open-close quick connectors or self-sealing quick connectors. Based on this selection, when the pipeline connection is disconnected, the corresponding plug or interface will automatically close, thereby preventing coolant leakage.

[0076] Reference Figure 7 and Figure 8 In this embodiment, the liquid-cooled socket 2251 is connected to the corresponding first collection interface 2131 after being plugged in, and the return socket 2171 is connected to the corresponding second collection interface 2132 after being plugged in, both are connected by several bolts.

[0077] The implementation principle of this application embodiment is as follows: Based on the structural design of the spiral heat exchanger tube 21, when the spiral heat exchanger tube 21 is working, the low-temperature coolant from the liquid cooling circulation assembly 22 enters the inlet pipe 214 through the quick connector 225 and the first collection interface 2131 from the first water inlet interface 2141. Since the inlet pipe 214 is designed to be close to the insulation layer 12 and is covered with a thermally conductive layer, the coolant can efficiently and directionally absorb the heat generated by the central conductor 11 as it spirals along the cable body 1 towards the end. In this process, the thermally conductive medium layer 216 filled inside the outer tube 213 ensures low thermal resistance heat conduction from the insulation layer 12 to the inlet pipe 214. When the coolant reaches the second collection interface 2132 at the other end of the spiral heat exchanger tube 21, the fluid is deflected from the first water outlet interface 2142 into the second water inlet interface 2151 by the action of the return component 217, and then flows into the water outlet pipe 215. During the reflux process, the insulation layer on the outside of the outlet pipe 215 effectively prevents the heated coolant from transferring heat back to the heat-conducting medium layer 216 or the inlet pipe 214, avoiding internal thermal short circuits between the inlet pipe 214 and the outlet pipe 215, thereby maximizing the heat exchange efficiency of the spiral heat exchange tube 21. Finally, the high-temperature coolant that has absorbed heat flows back to the first collection interface 2131 through the outlet pipe 215, and then returns to the liquid cooling circulation assembly 22 for cooling via the second outlet interface 2152 and the quick-connect fitting 225, completing one cycle. This design not only achieves efficient directional heat exchange, but also, through the cooperation of the quick-connect fitting 225 and the reflux component 217, allows the spiral heat exchange tube 21 to be connected to the liquid cooling circulation assembly 22 at only one end, simplifying cable installation, plugging and unplugging, and subsequent maintenance.

[0078] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be included within the scope of protection of this application.

Claims

1. A liquid-cooled smart charging cable, characterized in that, The utility model relates to a kind of liquid-cooled cable, including: Cable body (1), including center conductor (11), the center conductor (11) outside is wrapped with insulating layer (12), the insulating layer (12) outside is wrapped with outer sheath layer (13), the outer sheath layer (13) is spaced apart from the insulating layer (12) and forms liquid cooling cavity (14); Liquid cooling mechanism (2), including liquid cooling circulation assembly (22) and several spiral heat exchange pipes (21), the spiral heat exchange pipe (21) is located in the liquid cooling cavity (14), several spiral heat exchange pipes (21) are sequentially arranged along the length direction of the cable body (1), the spiral heat exchange pipe (21) is communicated with the liquid cooling circulation assembly (22), the liquid cooling circulation assembly (22) is used to drive cooling liquid to circulate in the spiral heat exchange pipe (21) and control the cooling liquid flow of each spiral heat exchange pipe (21) circulation; Temperature control mechanism (3), including controller (32) and several temperature sensors (31), the temperature sensor (31) is arranged on the insulating layer (12), several temperature sensors (31) are sequentially arranged along the length direction of the cable body (1), the temperature sensor (31) and the liquid cooling circulation assembly (22) are electrically connected with the controller (32).

2. The liquid-cooled intelligent charging cable according to claim 1, characterized in that, The spiral heat exchange pipe (21) is spirally arranged outside the insulating layer (12).

3. The liquid-cooled intelligent charging cable according to claim 2, characterized in that, The outer wall of the insulating layer (12) is provided with a spiral groove (121), and the spiral heat exchange pipe (21) is embedded in the spiral groove (121).

4. The liquid-cooled intelligent charging cable of claim 1, wherein, The spiral heat exchange pipe (21) includes an outer tube (213), the outer tube (213) is provided with an inlet pipe (214) and an outlet pipe (215), the length direction of the inlet pipe (214) and the outlet pipe (215) is arranged along the length direction of the outer tube (213). One end of the outer tube (213) extends out of the outer sheath layer (13), the outer tube (213) is connected with the liquid cooling circulation assembly (22), the inlet pipe (214) and the outlet pipe (215) are communicated with the liquid cooling circulation assembly (22), and the inlet pipe (214) and the outlet pipe (215) are communicated with each other away from the liquid cooling circulation assembly (22).

5. The liquid-cooled intelligent charging cable according to claim 4, characterized in that, The inlet pipe (214) is located on the side of the outlet pipe (215) close to the insulating layer (12).

6. The liquid-cooled intelligent charging cable according to claim 5, characterized in that, The inlet pipe (214) is provided with a heat-conducting layer outside, and the outlet pipe (215) is provided with a heat-insulating layer outside.

7. The liquid-cooled intelligent charging cable of claim 5, wherein, The outer tube (213) is filled with a heat-conducting medium layer (216), and the heat-conducting medium layer (216) wraps the inlet pipe (214) and the outlet pipe (215).

8. The liquid-cooled intelligent charging cable of claim 4, wherein, The outer tube (213) is provided with a first collection interface (2131) at one end and a second collection interface (2132) at the other end, the water inlet pipe (214) is connected to the first collection interface (2131) and the second collection interface (2132) respectively, and the water outlet pipe (215) is connected to the first collection interface (2131) and the second collection interface (2132) respectively; The first collection interface (2131) is located outside the outer sheath layer (13), and the first collection interface (2131) and the liquid cooling circulation assembly (22) are in plug-in fit and mutual communication; The second collection interface (2132) is plugged with a backflow device (217), and the water inlet pipe (214), the backflow device (217) and the water outlet pipe (215) are in sequence communication.

9. The liquid-cooled intelligent charging cable according to claim 8, characterized in that, The outer tube (213) extends to the outside of the outer sheath layer (13) at both ends along the length direction of the outer tube (213), and the first collection interface (2131) and the second collection interface (2132) are located outside the outer sheath layer (13). 10.A heat dissipation control method of a liquid-cooled intelligent charging cable, used for controlling the liquid-cooled intelligent charging cable according to any one of claims 1-9, characterized in that, The method further comprises the following steps: The temperature sensors (31) acquire temperature data of each section of the cable body (1) in real time and transmit the temperature data to the controller (32); the controller (32) compares the acquired temperature data with a preset high temperature limit value to determine whether the temperature of the corresponding section of the cable body (1) exceeds the preset high temperature limit value; when the temperature of the corresponding section of the cable body (1) exceeds the preset high temperature limit value, the controller (32) controls the liquid cooling circulation assembly (22) to increase the flow of the cooling liquid in the corresponding spiral heat exchange pipe (21) to reduce the temperature of the corresponding section of the cable body (1).

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