Terminal heat dissipation device of direct current fast charging base and heat dissipation control method thereof

Abstract

The application relates to a terminal heat dissipation device of a direct-current fast-charging charging base and a heat dissipation control method thereof. The device comprises a shell, a conductive terminal for electric energy transmission, a heat-conducting insulating container, an electromagnetic pump and a heat dissipation assembly. The heat-conducting insulating container and the electromagnetic pump form a closed circulation flow channel through a circulation pipeline, and the closed circulation flow channel is filled with liquid metal cooling medium. One end of the conductive terminal extends out of the shell and is connected with a charging gun, and the other end of the conductive terminal is used for being in contact with the heat-conducting insulating container. The heat generated by the conductive terminal during work can be directly transmitted to the liquid metal cooling medium in the heat-conducting insulating container. The heat dissipation assembly is arranged on the shell and is used for receiving the heat carried by the liquid metal cooling medium and dissipating the heat to the external environment. The application has the effect of improving the heat dissipation efficiency of the fast-charging charging base and the reliability of the system without increasing the system volume.

Description

Technical Field

[0001] This application relates to the field of DC fast charging thermal management, and in particular to a terminal heat dissipation device for a DC fast charging socket and a heat dissipation control method thereof. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the capacity and driving range of power batteries are constantly improving, and users' requirements for charging efficiency are increasing. DC fast charging power is evolving towards the megawatt level. The increase in charging power is accompanied by a significant increase in charging current. The resulting Joule heating effect causes the heat load of the core components of the charging system to rise sharply. Among them, the charging terminal is a key node for power transmission, and its operating temperature directly determines the upper limit of the charging system's power and operational safety.

[0003] Currently, the industry mainly uses two technical routes for heat dissipation of charging dock terminals: air cooling and traditional liquid cooling. Air cooling technology has a simple structure and low cost, but its heat dissipation capacity is limited and it is difficult to meet the heat dissipation requirements of high power density scenarios. Although traditional liquid cooling technology has a higher heat exchange efficiency than air cooling, it still has problems such as large system size, insufficient reliability, and slow response speed in practical applications, and cannot adapt to the development requirements of megawatt-level DC fast charging. Summary of the Invention

[0004] In order to improve the heat dissipation efficiency and system reliability of the fast charging dock without increasing the system size, this application provides a terminal heat dissipation device for a DC fast charging dock.

[0005] Firstly, the terminal heat dissipation device for a DC fast charging dock provided in this application adopts the following technical solution: A terminal heat dissipation device for a DC fast charging dock includes a housing and two conductive terminals for power transmission, as well as a thermally conductive insulating container, an electromagnetic pump, and a heat dissipation assembly. The thermally conductive insulating container and the electromagnetic pump are both installed in the internal cavity of the housing. The thermally conductive insulating container and the electromagnetic pump form a closed circulation channel through a circulation pipe, and the closed circulation channel is filled with a liquid metal cooling medium. One end of each conductive terminal extends out of the housing for insertion and engagement with a charging gun, and the other end of the conductive terminal contacts the thermally conductive insulating container. The heat generated by the conductive terminal during operation can be directly transferred to the liquid metal cooling medium through the thermally conductive insulating container. The electromagnetic pump drives the liquid metal cooling medium to flow within the closed circulation channel. The heat dissipation assembly is disposed on the housing and is used to receive the heat carried by the liquid metal cooling medium and dissipate it to the external environment.

[0006] By adopting the above technical solution, the thermally conductive insulating container, electromagnetic pump, and conductive terminals are integrated into the same housing, achieving an integrated and compact design of the terminal heat dissipation device. This significantly reduces the overall volume and allows the conductive terminals to directly contact the thermally conductive insulating container, eliminating the additional thermal resistance caused by the intermediate transition layer. This enables the heat generated by the conductive terminals to be directly transferred to the internal liquid metal cooling medium, significantly improving heat transfer efficiency. The electromagnetic pump drives the liquid metal to flow continuously in the closed circulation channel, ensuring that heat can be stably and efficiently transferred to the heat dissipation components and dissipated to the external environment, thus ensuring the stable operating temperature of the terminals under high-power charging conditions.

[0007] Optionally, the thermally conductive insulating container is made of ceramic material, which is selected from any one of aluminum nitride, aluminum oxide, zirconium oxide, beryllium oxide, and hexagonal boron nitride, and the liquid metal cooling medium is a gallium-based alloy.

[0008] By adopting the above technical solutions, the thermally conductive and insulating container is limited to ceramic materials such as aluminum nitride and alumina. These ceramic materials have excellent thermal conductivity, electrical insulation properties, and resistance to liquid metal corrosion. They can quickly conduct heat from the conductive terminals to the internal cooling medium, effectively isolate high voltage electricity from liquid metal, reduce the risk of electrical short circuits, and resist electrochemical corrosion caused by long-term immersion in liquid metal, preventing perforation and leakage of the container and extending the overall service life of the device. The variety of optional materials also provides flexible selection space for application scenarios with different cost and performance requirements. Gallium-based alloys are used as liquid metal cooling media. Their thermal conductivity is much higher than that of traditional ethylene glycol aqueous solutions and other coolants, which can absorb and transfer the heat generated by the conductive terminals more quickly. At the same time, gallium-based alloys are liquid at room temperature and have low kinematic viscosity, which can effectively reduce their flow resistance in the circulation channel and reduce the driving energy consumption of the electromagnetic pump. In addition, this cooling medium has a high boiling point and good chemical stability. It is not easy to volatilize and decompose in high-temperature working environments. It is safe, non-toxic, and will not cause environmental pollution. Its good conductivity also enables it to achieve efficient contactless driving through electromagnetic pumps.

[0009] Optionally, the internal space of the thermally conductive insulating container is divided into a liquid metal storage area and a buffer zone. The buffer zone is used to absorb pressure fluctuations generated by the flow of the liquid metal cooling medium. The interior of the thermally conductive insulating container is provided with flow-diverting ribs along the flow direction of the liquid metal, which divide the liquid metal storage area into adjacent independent sub-channels.

[0010] By adopting the above technical solution, the internal space of the thermally conductive and insulating container is divided into a liquid metal storage area and a buffer zone. The buffer zone can effectively absorb the pressure fluctuations generated by the liquid metal during start-up, shutdown, and flow, reduce the damage of hydraulic impact to the container wall and pipeline, and improve the stability and service life of the system. The diversion ribs set along the flow direction of the liquid metal divide the storage area into adjacent independent sub-channels, which can guide the liquid metal to flow evenly and smoothly, avoid the occurrence of flow dead zones and eddies, ensure that the liquid metal is evenly distributed in the container, and increase the heat exchange contact area between the liquid metal and the inner wall of the container, further improving the overall heat dissipation efficiency.

[0011] Optionally, a quick-connect interface is provided at the end of the circulation pipe corresponding to the thermally conductive insulating container. The quick-connect interface is used to connect to the end of the thermally conductive insulating container, and the cross-sectional area of ​​the quick-connect interface gradually increases along the direction from the circulation pipe to the thermally conductive insulating container.

[0012] By adopting the above technical solution, quick-connect interfaces are used to achieve rapid docking and assembly of the circulating pipeline and the end of the thermally conductive and insulated container, shortening the assembly time of the pipeline and container, and making the disassembly and maintenance of pipeline joints convenient and efficient. The cross-sectional area of ​​the quick-connect interface gradually increases from the pipeline to the container side. When the liquid metal flows through the interface, the flow cross section gradually increases and the flow velocity gradually slows down. Combined with the buffer zone built into the container end, the hydraulic impact of the medium flowing in can be smoothly reduced, the uniformity of the flow velocity of the medium entering and leaving the container can be optimized, the formation of eddies and turbulence at the interface position can be avoided, the pressure pulsation generated by the circulating medium can be reduced, the flow state of the liquid metal inside the container can be stabilized, the wear of the container and pipeline caused by fluid impact can be reduced, and the operational stability of the entire circulation loop can be improved.

[0013] Optionally, the electromagnetic pump is a DC conductive electromagnetic pump, which controls the circulation speed of the liquid metal cooling medium by adjusting the input current density and magnetic field strength.

[0014] By adopting the above technical solution, a DC conductive electromagnetic pump is used as the driving device for liquid metal. It directly drives the liquid metal flow through Lorentz force, without any mechanical moving parts or contact sealing structure. During operation, the noise is extremely low and there is no mechanical wear problem, which significantly improves the reliability and service life of the drive system. At the same time, this type of electromagnetic pump can precisely control the circulation speed of liquid metal by adjusting the input current density and magnetic field strength, realizing stepless adjustment of heat dissipation intensity. This allows the heat dissipation system to flexibly adapt to charging conditions of different power levels and meet the heat dissipation needs of all scenarios from low-power slow charging to megawatt-level fast charging.

[0015] Optionally, a closed-loop control unit is also included. The closed-loop control unit includes a temperature sensor, a current sensor, and a central controller. The temperature sensor is used to collect the operating temperature of the conductive terminal in real time, the current sensor is used to collect the operating current of the charging circuit in real time, and the central controller is electrically connected to the temperature sensor, the current sensor, and the electromagnetic pump respectively, and is used to dynamically adjust the driving power of the electromagnetic pump according to the collected temperature and current data.

[0016] By adopting the above technical solution and setting up a closed-loop control unit including a temperature sensor, a current sensor, and a central controller, the operating temperature of the conductive terminals and the operating current of the charging circuit can be collected in real time. The central controller dynamically adjusts the driving power of the DC conductive electromagnetic pump based on the collected dual-parameter data, so that the circulation speed of the liquid metal is precisely matched with the actual heat dissipation requirements. During high-current fast charging, the heat dissipation intensity can be quickly improved to prevent the conductive terminals from overheating and being damaged. During low-load charging, the driving power is reduced to save energy. At the same time, it can quickly respond to the temperature rise impact caused by instantaneous high current, ensuring that the conductive terminals always work within a safe temperature range.

[0017] Optionally, the heat dissipation component is a finned radiator, the finned radiator having an internal heat exchange channel communicating with a circulation pipe, and the finned radiator having an auxiliary heat dissipation interface for connecting to an external secondary cooling system.

[0018] By adopting the above technical solution and using a finned heat sink as the heat dissipation component, the dense fin structure on its surface significantly increases the heat exchange surface area with the outside air, which can significantly improve the heat exchange efficiency of natural convection and forced convection. The heat exchange channels opened inside the heat sink are directly connected to the closed circulation channels of the liquid metal, ensuring that heat can be quickly transferred from the liquid metal to the heat sink body. The auxiliary heat dissipation interface set on the finned heat sink can be connected to an external secondary cooling system under extreme high-power charging conditions to further improve the heat dissipation capacity, enabling the device to stably support the demand for higher power DC fast charging.

[0019] Optionally, the housing is provided with an adapter slot, and the heat dissipation component is provided with an adapter block. The heat dissipation component is snapped into the adapter slot through the adapter block, and the heat dissipation component is installed on the housing by bolts.

[0020] By adopting the above technical solution, the adapter slot on the shell and the adapter block on the heat dissipation component are used to achieve snap-fit ​​positioning, which can ensure the installation accuracy of the heat dissipation component and the shell, and ensure that the internal heat exchange flow channel and the liquid metal circulation flow channel are accurately connected, avoiding flow channel blockage or leakage caused by misalignment. At the same time, the heat dissipation component is further tightened to the shell with bolts, which not only ensures the reliability and sealing of the connection, but also makes the disassembly and replacement of the heat dissipation component more convenient, without having to disassemble other components inside the shell, which greatly reduces the later maintenance cost and difficulty.

[0021] Secondly, this application also provides a heat dissipation control method, which adopts the following technical solution: the terminal heat dissipation device applied to the above-mentioned DC fast charging dock includes the following steps: S1: Real-time acquisition of the operating temperature of the conductive terminals via a temperature sensor; S2: Transmit the collected operating temperature data to the central controller; S3: The central controller compares the received operating temperature with the preset temperature threshold. S4: When the operating temperature exceeds the preset temperature threshold, the central controller increases the input current density and magnetic field strength of the DC conductive electromagnetic pump to accelerate the circulation speed of the liquid metal cooling medium, and at the same time starts the external secondary cooling system through the auxiliary heat dissipation interface. S5: When the operating temperature is less than or equal to the preset temperature threshold, the central controller reduces the drive power of the DC conductive electromagnetic pump and slows down the circulation speed of the liquid metal cooling medium.

[0022] By adopting the above technical solution, and by collecting the working temperature of the conductive terminals in real time and comparing it with a preset threshold, the driving power of the DC conductive electromagnetic pump can be dynamically adjusted according to the actual heat dissipation requirements, thereby achieving precise control of heat dissipation intensity. When the temperature exceeds the standard, it not only accelerates the circulation speed of liquid metal to improve the basic heat dissipation capacity, but also simultaneously starts the external secondary cooling system through the auxiliary heat dissipation interface, forming a graded heat dissipation mechanism. This can effectively cope with the severe temperature rise impact under extreme high-power charging conditions, ensuring that the working temperature of the conductive terminals is always within a safe range. At the same time, when the temperature is normal, the driving power is reduced, achieving energy-saving operation.

[0023] Optionally, step S1 further includes collecting the operating current of the charging circuit in real time through a current sensor. In step S3, the central controller compares the operating current with a preset current threshold. When the operating temperature is greater than a preset temperature threshold or the operating current is greater than a preset current threshold, the action of step S4 is executed. The method is continuously executed in a loop throughout the entire charging process until the charging is completed.

[0024] By adopting the above technical solution and increasing the acquisition and judgment of the charging circuit operating current, the control logic can simultaneously adjust the heat dissipation based on both temperature and current dimensions, further improving the accuracy and timeliness of temperature control. It can predict the temperature rise trend brought about by high current charging in advance and avoid sudden temperature rise. The control steps are continuously executed in a loop throughout the entire charging process, realizing dynamic temperature control at all times. This ensures the heat dissipation effect and operational safety from the start to the end of charging, and effectively extends the service life of the conductive terminals and the entire heat dissipation device.

[0025] In summary, this application includes at least one of the following beneficial technical effects: By directly contacting the terminals with the ceramic container to conduct heat, the intermediate thermal resistance is eliminated. Combined with high thermal conductivity gallium-based liquid metal, flow shunt ribs to optimize the flow field, and dynamic speed regulation of the electromagnetic pump, along with a graded heat dissipation mechanism, the overall heat dissipation capacity is significantly enhanced, and it can stably support megawatt-level high-power DC fast charging.

[0026] Ceramic thermally conductive and insulating containers achieve complete isolation between high-voltage components and cooling media, fundamentally avoiding the risk of short circuits; DC conductive electromagnetic pumps with no moving mechanical parts operate stably and without wear; dual-parameter closed-loop temperature control can quickly respond to temperature rise shocks, effectively extending the service life of the device.

[0027] The overall design adopts a modular quick-connect structure, and the standardized interface can be adapted to different charging sockets. The heat dissipation components are positioned by snap-fit ​​and secured with bolts to achieve quick disassembly without disassembling the internal pipes, which greatly reduces maintenance costs and facilitates mass production and upgrade iteration. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the terminal heat dissipation device of the DC fast charging dock.

[0029] Figure 2 This is a schematic diagram showing the positional relationship between the conductive terminals and the electromagnetic pump.

[0030] Figure 3 yes Figure 2 Cross-sectional view of the insulating container for the middle conductor.

[0031] Figure 4 This is a cross-sectional view of the heat dissipation components, used to show the heat exchange channels and auxiliary heat dissipation interfaces.

[0032] Figure 5 This is a flowchart of the heat dissipation control method.

[0033] Reference numerals: 1. Housing; 11. Adapter slot; 2. Conductive terminal; 3. Thermally conductive insulating container; 31. Liquid metal storage area; 32. Buffer zone; 33. Diverting rib; 4. Electromagnetic pump; 5. Heat dissipation assembly; 51. Adapter block; 52. Heat exchange channel; 53. Auxiliary heat dissipation interface; 6. Quick-connect interface; 7. Circulation pipe. Detailed Implementation

[0034] The following is in conjunction with the appendix Figure 1-5 This application will be described in further detail.

[0035] This application discloses a terminal heat dissipation device for a DC fast charging dock. (See also...) Figure 1 and Figure 2A terminal heat dissipation device for a DC fast charging base includes a housing 1, two conductive terminals 2, a thermally conductive insulating container 3, an electromagnetic pump 4, a heat dissipation assembly 5, and a closed-loop control unit. The thermally conductive insulating container 3 and the electromagnetic pump 4 are both fixedly installed in the housing 1 by bolts. The two conductive terminals 2 are installed in the housing 1 by bolts. One end of the conductive terminal 2 extends out of the outer wall of the housing 1. The exposed end of the conductive terminal 2 is used to connect with the charging gun. The other end of the conductive terminal 2 is used to abut against the outer wall of the thermally conductive insulating container 3.

[0036] Reference Figure 2 and Figure 3 The thermally conductive insulating container 3 is made of ceramic material, which can be any one of aluminum nitride, aluminum oxide, zirconium oxide, beryllium oxide, or hexagonal boron nitride. The thermally conductive insulating container 3 and the electromagnetic pump 4 form a closed circulation channel through the circulation pipe 7. A quick-connect interface 6 is fixedly provided at the end of the circulation pipe 7 facing the thermally conductive insulating container 3. The cross-section of the quick-connect interface 6 gradually increases from the circulation pipe 7 to the thermally conductive insulating container 3. The quick-connect interface 6 is used to connect to the thermally conductive insulating container 3. The closed circulation channel is filled with a liquid metal cooling medium, which is gallium nitride liquid metal. The heat generated when the conductive terminal 2 is working is directly transferred to the gallium nitride liquid metal cooling medium through the thermally conductive insulating container 3. The internal space of the thermally conductive insulating container 3 is divided into a liquid metal storage area 31. The buffer zone 32 is used to absorb pressure fluctuations generated by the flow of liquid metal cooling medium. A flow-diverting rib 33 is provided inside the thermally conductive and insulating container 3. The length direction of the flow-diverting rib 33 is parallel to the movement direction of the liquid metal cooling medium in the thermally conductive and insulating container 3. The flow-diverting rib 33 is located at the liquid metal storage area 31 and is arranged along the liquid metal flow direction, dividing the liquid metal storage area 31 into two adjacent independent sub-channels. The ends of all sub-channels along the medium flow direction are interconnected and converged. The converged liquid metal flows into the circulation pipe 7 through the quick-connect interface 6. This interconnected and converged structure can balance the medium flow of each sub-channel, avoid eddies and dead zones inside the cavity, and increase the overall heat exchange contact area between the liquid metal and the inner wall of the ceramic container.

[0037] Reference Figure 3 and Figure 4The housing 1 has adapter slots 11 on opposite sides. The heat dissipation assembly 5 is a finned heat sink. Two adapter blocks 51 are fixedly installed on the heat dissipation assembly 5, corresponding to the two adapter slots 11. The heat dissipation assembly 5 is snapped into the adapter slots 11 by the adapter blocks 51 and is fixedly installed on the housing 1 by bolts. A heat exchange channel 52 is provided inside the heat dissipation assembly 5, which is connected to the circulation pipe 7. The heat dissipation assembly 5 is provided with an auxiliary heat dissipation interface 53 for connecting to an external secondary cooling system. The electromagnetic pump 4 is a DC conductive electromagnetic pump 4. The electromagnetic pump 4 is equipped with a driving electrode that extends into the cavity through the side wall of the thermally conductive and insulating ceramic container and directly contacts the liquid metal cooling medium, thereby supplying a driving current to the liquid metal. An insulating and sealed structure is set at the position where the electrode penetrates the ceramic wall to achieve hermetically sealed connection and electrical isolation at the electrode mounting point. The entire driving circuit of the electromagnetic pump 4 is a low-voltage circuit, which is electrically isolated from the high-voltage charging circuit carried by the conductive terminal 2. The electromagnetic pump 4 controls the circulation speed of the liquid metal cooling medium by adjusting the input current density and magnetic field strength.

[0038] The closed-loop control unit includes a temperature sensor, a current sensor, and a central controller. The temperature sensor is used to collect the operating temperature of the conductive terminal 2 in real time, and the current sensor is used to collect the operating current of the charging circuit in real time. The central controller is electrically connected to the temperature sensor, the current sensor, and the electromagnetic pump 4, and is used to dynamically adjust the driving power of the electromagnetic pump 4 according to the collected temperature and current data.

[0039] The implementation principle of the terminal heat dissipation device of the DC fast charging base in this application embodiment is as follows: After the charging gun is plugged into the outer end of the conductive terminal 2 and the power supply is turned on, the conductive terminal 2 is powered on and continuously generates heat. The heat is closely attached to the outer wall of the thermally conductive insulating container 3 and directly introduced into the gallium nitride liquid metal cooling medium inside the container through the ceramic substrate. The DC conductive electromagnetic pump 4 is powered on and started, and under the action of the electromagnetic field, it drives the liquid metal to flow along the closed circulation channel. The medium flows from the thermally conductive insulating container 3 into the circulation pipe 7 through the end-expanding quick-connect interface 6, and then into the heat exchange channel 52 inside the finned heat dissipation assembly 5. The heat carried by the gallium nitride liquid metal is released through heat exchange with the ambient air through the heat sink fins. The cooled gallium nitride liquid metal flows back to the thermally conductive insulating container 3 along the circulation pipe, completing one round of heat exchange.

[0040] When gallium nitride liquid metal flows through quick-connect interface 6, the cross-sectional area of ​​the interface gradually increases from the pipeline to the container, the medium flow cross section expands gently and the flow velocity gradually slows down. In conjunction with the buffer zone 32 inside the thermally conductive and insulating container 3 to absorb the fluid pressure impact, the flow divider ribs 33 divide the storage area into two independent sub-channels, guide the liquid metal to flow evenly, avoid eddies and dead zones, and stabilize the medium flow state inside the cavity.

[0041] The closed-loop control unit monitors the equipment's operating status in real time throughout the process: a temperature sensor attached to the conductive terminal 2 continuously collects the terminal's real-time temperature, and a current sensor connected in series with the charging circuit synchronously collects the circuit's operating current. Both monitoring data are transmitted to the central controller in real time. The central controller has preset temperature and current thresholds and compares the measured data with the preset parameters to determine whether either the terminal temperature or the circuit current exceeds the set threshold. When either the terminal temperature or the circuit current exceeds the set threshold, the controller increases the input current density and magnetic field strength of the electromagnetic pump 4 to accelerate the liquid metal circulation speed and improve heat dissipation efficiency. If the load power is too high and conventional air cooling is insufficient, an external secondary cooling system can be connected through the auxiliary heat dissipation interface 53 on the side of the heat dissipation component 5 to enhance the heat dissipation capacity. When the terminal temperature and circuit current fall back below the threshold, the central controller reduces the output power of the electromagnetic pump 4 to decrease the medium circulation speed and reduce unnecessary power consumption.

[0042] The heat dissipation component 5 is secured by the adapter block 51 engaging with the adapter slot 11 of the housing 1 and then being locked in place with bolts. When maintenance and disassembly are required, the heat dissipation component 5 can be removed by simply removing the fixing bolts, without disassembling the internal thermally conductive insulating container 3 and electromagnetic pump 4 components of the housing 1. The entire heat dissipation cycle and intelligent control process run continuously with the charging operation until charging is completed and the equipment is powered off and shut down.

[0043] This application also discloses a heat dissipation control method, which is applied to the terminal heat dissipation device of the aforementioned DC fast charging dock, and includes the following steps: S1: The operating temperature of conductive terminal 2 is collected in real time by a temperature sensor, and the operating current of the charging circuit is collected in real time by a current sensor. S2: Transmit the collected operating temperature data to the central controller; S3: The central controller compares the received operating temperature with the preset temperature threshold, and at the same time compares the operating current with the preset current threshold. S4: When the operating temperature exceeds the preset temperature threshold, the central controller increases the input current density and magnetic field strength of the DC conductive electromagnetic pump 4 to accelerate the circulation speed of the liquid metal cooling medium, and at the same time starts the external secondary cooling system through the auxiliary heat dissipation interface 53. S5: When the operating temperature is less than or equal to the preset temperature threshold, the central controller reduces the drive power of the DC conductive electromagnetic pump 4 and slows down the circulation speed of the liquid metal cooling medium.

[0044] In step S3, the central controller compares the operating current with a preset current threshold. When the operating temperature is greater than the preset temperature threshold or the operating current is greater than the preset current threshold, the action of step S4 is executed. The method is continuously executed in a loop throughout the entire charging process until the charging is completed.

[0045] The implementation principle of the heat dissipation control method in this application embodiment is as follows: This heat dissipation control method is adapted to the operation of the terminal heat dissipation device of the aforementioned DC fast charging charging base. It continuously executes in a closed loop throughout the entire charging cycle of the equipment, realizing intelligent dynamic heat dissipation control of the liquid metal heat dissipation system. After the charging operation starts, the system synchronously enters the monitoring and control state. The real-time operating temperature of the conductive terminal 2 is collected in real time through the temperature sensor, and the real-time operating current of the charging circuit is continuously collected by the current sensor. The collected temperature data and current data are synchronously transmitted to the central controller in real time.

[0046] The central controller has built-in preset temperature and current thresholds, which can simultaneously compare and judge the collected temperature and current parameters in two dimensions. If either parameter exceeds the limit, the control logic for enhanced heat dissipation will be activated. When the operating temperature of the conductive terminal 2 is detected to be greater than the preset temperature threshold, or the operating current of the charging circuit is detected to be greater than the preset current threshold, the current charging condition is determined to be a high-load, high-heat-risk condition. The central controller immediately increases the input current density and magnetic field strength of the DC conductive electromagnetic pump 4. By changing the excitation parameters of the electromagnetic pump 4, the driving force is increased, and the circulation speed of the liquid metal cooling medium inside the closed circulation channel is accelerated, which greatly improves the heat exchange cycle efficiency and quickly removes the heat accumulated in the conductive terminal 2. At the same time, the auxiliary heat dissipation interface 53 of the heat dissipation component 5 is linked to start the external secondary cooling system for auxiliary heat dissipation, further improving the extreme heat dissipation capacity and suppressing the terminal temperature rise problem under high-power fast charging conditions.

[0047] When the charging load decreases, the operating temperature of the conductive terminal 2 drops to or below the preset temperature threshold, and the charging current is within the normal range, the central controller automatically reduces the overall drive power of the DC conductive electromagnetic pump 4, reduces the circulation speed of the liquid metal cooling medium, avoids the heat dissipation system from running at high power continuously and generating ineffective energy consumption, and achieves energy-saving operation.

[0048] The entire control process, which integrates data acquisition, parameter comparison, power adjustment, and auxiliary heat dissipation, is continuously executed throughout the entire charging process. It can adapt to the dynamic fluctuations of charging power in real time, predict the potential temperature rise caused by high current in advance, solve the problem of lagging single temperature control, and keep the working temperature of conductive terminal 2 stably controlled within a safe range throughout the entire process, ensuring the continuous, stable, and safe operation of the DC fast charging equipment until the charging operation is completely completed.

[0049] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A terminal heat dissipation device for a DC fast charging base, comprising a housing (1) and two conductive terminals (2) for power transmission, characterized in that, It also includes a thermally conductive insulating container (3), an electromagnetic pump (4), and a heat dissipation assembly (5); the thermally conductive insulating container (3) and the electromagnetic pump (4) are both installed in the internal cavity of the housing (1), and the thermally conductive insulating container (3) and the electromagnetic pump (4) form a closed circulation channel through a circulation pipe (7), which is filled with liquid metal cooling medium; one end of the conductive terminal (2) extends out of the outside of the housing (1) for insertion and cooperation with the charging gun, and the other end of the conductive terminal (2) is used to contact the thermally conductive insulating container (3). The heat generated during operation can be directly transferred to the liquid metal cooling medium through the thermally conductive insulating container (3); the electromagnetic pump (4) is used to drive the liquid metal cooling medium to flow in a closed circulation channel; the heat dissipation component (5) is disposed on the shell (1), and the heat dissipation component (5) is used to receive the heat carried by the liquid metal cooling medium and dissipate the heat to the external environment; the thermally conductive insulating container (3) is made of ceramic material, which is selected from any one of aluminum nitride, alumina, zirconium oxide, beryllium oxide, and hexagonal boron nitride, and the liquid metal cooling medium is a gallium-based alloy.

2. The terminal heat dissipation device of a DC fast charging dock according to claim 1, characterized in that: The internal space of the thermally conductive insulating container (3) is divided into a liquid metal storage area (31) and a buffer zone (32). The buffer zone (32) is used to absorb pressure fluctuations generated by the flow of liquid metal cooling medium. The interior of the thermally conductive insulating container (3) is provided with flow-diverting ribs (33) along the flow direction of liquid metal. The flow-diverting ribs (33) separate the liquid metal storage area (31) into adjacent independent sub-channels.

3. The terminal heat dissipation device for a DC fast charging dock according to claim 1, characterized in that: The circulation pipe (7) is provided with a quick-connect interface (6) at the end corresponding to the thermally conductive insulating container (3). The quick-connect interface (6) is used to connect to the end of the thermally conductive insulating container (3). The cross-sectional area of ​​the quick-connect interface (6) gradually increases along the direction from the circulation pipe (7) to the thermally conductive insulating container (3).

4. The terminal heat dissipation device for a DC fast charging dock according to claim 1, characterized in that: The electromagnetic pump (4) is a DC conductive electromagnetic pump (4). The electromagnetic pump (4) controls the circulation speed of the liquid metal cooling medium by adjusting the input current density and magnetic field strength.

5. The terminal heat dissipation device for a DC fast charging dock according to claim 4, characterized in that: It also includes a closed-loop control unit, which includes a temperature sensor, a current sensor and a central controller. The temperature sensor is used to collect the working temperature of the conductive terminal (2) in real time, the current sensor is used to collect the working current of the charging circuit in real time, and the central controller is electrically connected to the temperature sensor, the current sensor and the electromagnetic pump (4) respectively, and is used to dynamically adjust the driving power of the electromagnetic pump (4) according to the collected temperature and current data.

6. The terminal heat dissipation device for a DC fast charging dock according to claim 1, characterized in that: The heat dissipation component (5) is a finned radiator. The finned radiator has a heat exchange channel (52) that communicates with the circulation pipe (7) inside, and the finned radiator is provided with an auxiliary heat dissipation interface (53) that connects to the external secondary cooling system.

7. The terminal heat dissipation device for a DC fast charging dock according to claim 1, characterized in that: The housing (1) has an adapter slot (11) and the heat dissipation component (5) has an adapter block (51). The heat dissipation component (5) is snapped into the adapter slot (11) through the adapter block (51) and the heat dissipation component (5) is installed on the housing (1) by bolts.

8. A heat dissipation control method, characterized in that: The terminal heat dissipation device applied to the DC fast charging dock of claim 5 includes the following steps: S1: The working temperature of the conductive terminal (2) is collected in real time by a temperature sensor; S2: Transmit the collected operating temperature data to the central controller; S3: The central controller compares the received operating temperature with the preset temperature threshold. S4: When the operating temperature is greater than the preset temperature threshold, the central controller increases the input current density and magnetic field strength of the DC conductive electromagnetic pump (4) to accelerate the circulation speed of the liquid metal cooling medium, and at the same time starts the external secondary cooling system through the auxiliary heat dissipation interface (53). S5: When the operating temperature is less than or equal to the preset temperature threshold, the central controller reduces the driving power of the DC conductive electromagnetic pump (4) and slows down the circulation speed of the liquid metal cooling medium.

9. A heat dissipation control method according to claim 8, characterized in that, Step S1 also includes real-time acquisition of the operating current of the charging circuit through a current sensor. In step S3, the central controller compares the operating current with a preset current threshold. When the operating temperature is greater than the preset temperature threshold or the operating current is greater than the preset current threshold, the action of step S4 is executed. The method is continuously executed in a loop throughout the entire charging process until the charging is completed.

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