Liquid cooling integrated cable for 800A charging gun

Abstract

A liquid-cooled integrated cable for an 800A charging gun is characterized in that a DC + liquid-cooled charging wire, a DC-liquid-cooled charging wire, a grounding wire and a plurality of auxiliary wires are wrapped in an insulating jacket of the liquid-cooled integrated cable, cooling liquid channels and wires are arranged in the DC + liquid-cooled charging wire and the DC-liquid-cooled charging wire, and the cooling liquid channels and the wires are connected between liquid-cooled terminals and liquid-cooled electrodes. The number of the DC + liquid cooling charging wires is two, the number of the DC-liquid cooling charging wires is two, and the two cooling liquid channels in the two DC + liquid cooling charging wires or the two DC-liquid cooling charging wires are communicated through a liquid cooling terminal to form a cooling loop. Under the condition that the liquid cooling integrated cable safely bears 800A current, the wire diameter is greatly reduced, the wire diameter is only 26mm, and the bending radius is within 200mm. According to the liquid cooling integrated cable, the layout structure of each wire is optimized, gaps are reduced, the roundness of the cable is increased, and anisotropy of the cable in the bending direction is eliminated. The liquid-cooled integrated cable has the advantages of being thin, light and flexible, and the flexibility and experience feeling of charging operation are greatly improved.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy electric vehicle charging, in particular to a liquid-cooled integrated cable for an 800A charging gun. Background Art

[0002] At present, the power of charging piles has reached 480 kW and 600 kW. For a 600 kW charging pile, the charging cable needs to carry a maximum current of 800A. If a charging cable with natural heat dissipation is used, the wire diameter will be too large, the weight will be too large, and the cable will be difficult to bend, affecting the charging operation experience.

[0003] Currently, only liquid cooling technology can improve the carrying capacity of charging cables without excessively increasing the wire diameter. Figure 1 The figure shows a cross-sectional schematic diagram of an existing liquid cooling cable. Figure 1 It can be seen that, regardless of the series cooling method or the parallel cooling method, a DC+ liquid-cooled charging line 2, a DC-liquid-cooled charging line 3, a grounding line 4 and several auxiliary lines 5 are wrapped in the insulating outer sheath 1 of the liquid-cooled cable. Since a cooling liquid channel is provided in the DC+ liquid-cooled charging line 2 and the DC-liquid-cooled charging line 3, the wire diameters of the DC+ liquid-cooled charging line 2 and the DC-liquid-cooled charging line 3 are much thicker than the wire diameters of the grounding line 4 and the auxiliary line 5, which causes the following defects in the layout of the cable: 1. There are a large number of gaps in the cable, which affects the roundness of the cable; 2. The diameter of the DC+ liquid-cooled charging line and the DC-liquid-cooled charging line determines the wire diameter of the cable, which makes the cable wire diameter too large and difficult to bend, affecting the charging operation experience; 3. The cable can only bend in one direction, affecting the flexibility of the charging operation. In summary, the existing liquid-cooled cables need to be improved. Utility Model Content

[0004] In order to overcome the shortcomings of the background technology, the utility model discloses a liquid-cooled integrated cable for an 800A charging gun, which adopts the following technical solutions:

[0005] A liquid-cooled integrated cable for an 800A charging gun, wherein a DC+ liquid-cooled charging line, a DC- liquid-cooled charging line, a grounding line and several auxiliary lines are wrapped in its insulating outer sheath, wherein a DC+ cooling liquid channel and a DC+ wire are provided in the DC+ liquid-cooled charging line, and the DC+ cooling liquid channel and the DC+ wire are connected between the DC+ liquid-cooled terminal and the DC+ liquid-cooled electrode, and a DC- cooling liquid channel and a DC- wire are provided in the DC- liquid-cooled charging line, and the DC- cooling liquid channel and the DC- wire are connected between the DC- liquid-cooled terminal and the DC- liquid-cooled electrode. There are two DC+ liquid-cooled charging lines and two DC- liquid-cooled charging lines, and the DC+ cooling liquid channels in the two DC+ liquid-cooled charging lines are connected in the DC+ liquid-cooled terminal to form a cooling circuit; the DC- cooling liquid channels in the two DC- liquid-cooled charging lines are connected in the DC- liquid-cooled terminal to form a cooling circuit.

[0006] After implementing the above technical solution, the beneficial effects are as follows: the DC+ liquid-cooled charging cable and the DC- liquid-cooled charging cable have their own independent cooling circuits. After turning on the liquid cooler, the coolant can circulate and cool the DC+ wire and DC- wire, and take away the heat generated by the DC+ wire and DC- wire due to conduction.

[0007] Under the same load-bearing capacity, the wire diameter of two thin charging cables is 0.7 times that of one thick charging cable, which can reduce the wire diameter of existing liquid-cooled integrated cables by 30%. Moreover, the area of ​​contact between the wires of two thin charging cables and the coolant is 1.4 times that of one thick charging cable, so under the same cooling conditions, the coolant channel can be made thinner.

[0008] The wire diameter of the charging cable determines the wire diameter of the entire cable. For this liquid-cooled integrated cable, under the condition of safely carrying 800A current, the cross-sectional area of ​​the DC+ wire and the DC- wire is 30 square millimeters, the wire diameter of the DC+ liquid-cooled charging cable and the DC- liquid-cooled charging cable is 8-9mm, and the wire diameter of the entire liquid-cooled integrated cable can be as small as 26mm.

[0009] To further improve the technical solution, observing the cross-section of the liquid-cooled integrated cable, there is one grounding wire, which is located in the center of the liquid-cooled integrated cable; two DC+ liquid-cooled charging wires and two DC- liquid-cooled charging wires are closely arranged circumferentially with the grounding wire as the center; the auxiliary wires are evenly filled in the gaps between the DC+ liquid-cooled charging wire, DC- liquid-cooled charging wire and the insulating outer sheath.

[0010] After implementing the above technical solution, the following beneficial effects can be produced:

[0011] 1. The DC+ liquid-cooled charging cable, DC- liquid-cooled charging cable and auxiliary cable in this liquid-cooled integrated cable are closely arranged around the grounding wire, leaving a very small gap, which increases the roundness of the cable.

[0012] 2. Since the cable is symmetrical about the center, there is no anisotropy in the bending direction.

[0013] 3. Since the wire diameter of the liquid-cooled integrated cable is greatly reduced and there is no anisotropy in the bending direction, the arrangement of the liquid-cooled integrated cable greatly improves the flexibility and experience of the charging operation.

[0014] To further improve the technical solution, the wire diameter of the DC+ liquid-cooled charging cable is equal to the wire diameter of the DC- liquid-cooled charging cable, and the wire diameters of each auxiliary line are the same.

[0015] After implementing the above technical solution, the beneficial effects are: the wire diameter of the DC+ liquid-cooled charging line is equal to the wire diameter of the DC- liquid-cooled charging line. First, the DC+ liquid-cooled charging line and the DC- liquid-cooled charging line can be closely arranged in the same circle, and second, the DC+ liquid-cooled charging line and the DC- liquid-cooled charging line can carry the same charging current. The wire diameters of the auxiliary lines are the same, which is conducive to reducing the types of wires and facilitating production.

[0016] To further improve the technical solution, the ratio of the wire diameter of the ground wire to the wire diameter of the DC+liquid-cooled charging wire is 0.414.

[0017] After implementing the above technical solution, the beneficial effect is: the ratio of the wire diameter of the grounding wire to the wire diameter of the DC+ liquid-cooled charging wire is 0.414, which can make the grounding wire in close contact with the DC+ liquid-cooled charging wire and the DC- liquid-cooled charging wire without leaving any gaps.

[0018] To further improve the technical solution, there are twenty auxiliary wires, and the twenty auxiliary wires are grouped into five and evenly filled in the gaps between the DC+ liquid-cooled charging wire, the DC- liquid-cooled charging wire and the insulating outer sheath.

[0019] After the above technical solution is implemented, the beneficial effects are as follows: such a layout, firstly, makes full use of the gaps, and secondly, the central symmetrical structure is conducive to eliminating the anisotropy of the cable.

[0020] To further improve the technical solution, among the twenty auxiliary lines, four are temperature data transmission lines, namely T1+ line, T1- line, T2+ line and T2- line; four are electronic lock connection lines, namely PIN1 line, PIN2 line, EL+ line and EL- line; four are shielding lines, namely CC1 line, CC2 line, S+ line and S- line; of the remaining eight auxiliary lines, four are connected in parallel to form an A+ auxiliary power line, and four are connected in parallel to form an A- auxiliary power line.

[0021] After implementing the above technical solution, the beneficial effect is that the A+ auxiliary power line and the A- auxiliary power line are designed to carry the largest current except for the charging line and the grounding line, but increasing the wire diameter of the A+ auxiliary power line and the A- auxiliary power line is not conducive to the overall cable layout. Connecting four wires in parallel into one A+ auxiliary power line and four wires in parallel into one A- auxiliary power line can improve the rationality of the overall cable layout while ensuring the carrying current.

[0022] To further improve the technical solution, a wrapping tape is provided between the insulating outer sheath and the DC+ liquid-cooled charging cable, the DC- liquid-cooled charging cable, and the auxiliary cable, and the wrapping tape is formed by winding a non-woven tape or a metal foil tape.

[0023] After the implementation of the above technical solution, the beneficial effect produced is: through the winding of the wrapping tape, the DC+ liquid-cooled charging cable, the DC- liquid-cooled charging cable, and the auxiliary cable can be shaped and protected.

[0024] To further improve the technical solution, filling ropes are filled in the gaps between the DC+ liquid-cooled charging cable, the DC- liquid-cooled charging cable and the insulating outer sheath.

[0025] After the above technical solution is implemented, the beneficial effects produced are: first, the filling rope is used as a filler to fill the gap, which is beneficial to improve the roundness of the cable; second, the filling rope can improve the tensile strength of the entire cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Attached Figure 1 Shown is a schematic cross-sectional view of an existing liquid cooling cable.

[0027] Attached Figure 2 What is shown is a cross-sectional schematic diagram of the liquid-cooled integrated cable in Example 1.

[0028] Attached Figure 3 Shown is a schematic diagram of the structure of a DC+liquid-cooled charging cable.

[0029] Attached Figure 4 Shown is a schematic diagram of the connection between the DC+ liquid-cooled charging line and the liquid-cooled electrodes and liquid-cooled terminals.

[0030] Attached Figure 5 Shown is a schematic diagram of the connection between the DC-liquid cooling charging line and the liquid cooling electrodes and liquid cooling terminals.

[0031] Attached Figure 6 Shown is a cross-sectional schematic diagram of the liquid-cooled integrated cable in Example 2.

[0032] Attached photos

[0033] 1. Insulation outer cover;

[0034] 2. DC+liquid cooling charging cable; 21. DC+cooling liquid channel; 22. DC+conducting wire; 23. insulating jacket;

[0035] 3. DC-liquid cooling charging cable; 31. DC-cooling liquid channel; 32. DC-conductor;

[0036] 4. Ground wire;

[0037] 5. Auxiliary lines;

[0038] 6. DC+ liquid-cooled electrode; 61. liquid inlet; 62. liquid outlet;

[0039] 7. DC+ liquid cooling terminal; 71. Cooling chamber;

[0040] 8. DC-liquid-cooled electrode; 81. liquid inlet; 82. liquid outlet;

[0041] 9. DC-liquid cooling terminal; 91. Cooling chamber;

[0042] 10. Filling rope. DETAILED DESCRIPTION

[0043] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention. It should be noted that in the description of the present invention, the terms "front", "rear", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside" and the like indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings, which are only for the convenience of description, rather than indicating or implying that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. It should also be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected, or indirectly connected through an intermediate medium, or the internal connection of two components. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances. Embodiment 1:

[0044] See attached Figure 2 A liquid-cooled integrated cable for an 800A charging gun, wherein two DC+ liquid-cooled charging cables 2, two DC- liquid-cooled charging cables 3, a grounding cable 4 and twenty auxiliary cables 5 are wrapped in an insulating outer blanket 1.

[0045] By the attached Figure 2It can be seen that there is only one grounding wire 4, which is located in the center of the liquid-cooled integrated cable. The wire diameter of the DC+ liquid-cooled charging wire 2 is equal to the wire diameter of the DC- liquid-cooled charging wire 3. The two DC+ liquid-cooled charging wires 2 and the two DC- liquid-cooled charging wires 3 are closely arranged circumferentially with the grounding wire 4 as the center. The wire diameters of the twenty auxiliary wires 5 are the same, and the auxiliary wires 5 are grouped in five, evenly filling the four gaps between the DC+ liquid-cooled charging wire 2, the DC- liquid-cooled charging wire 3 and the insulating outer sheath 1. Obviously, this layout makes the DC+ liquid-cooled charging wire 2, the DC- liquid-cooled charging wire 3 and the auxiliary wire 5 closely arranged around the grounding wire 4, leaving a very small gap, which not only increases the roundness of the cable, but also eliminates the anisotropy of the cable in the bending direction.

[0046] See attached Figure 3 The DC+ liquid-cooled charging cable 2 is composed of an insulating jacket 23 and a DC+ conductor 22. The annular channel between the insulating jacket 23 and the DC+ conductor 22 is a DC+ coolant channel 21 for the coolant to flow. The outer layer of the DC+ conductor 22 is wrapped with a copper wire braided mesh, which is used to prevent the soft conductor 22 from loosening and blocking the coolant channel 21.

[0047] See attached Figure 4 When in use, two DC+ liquid-cooled charging wires 2 are connected between the DC+ liquid-cooled terminal 7 and the DC+ liquid-cooled electrode 6. Among them, two DC+ wires 22 are connected in parallel between the DC+ liquid-cooled terminal 7 and the DC+ liquid-cooled electrode 6 to carry the charging current together. In this embodiment, the two ends of the DC+ wire 22 are crimped on the inner wall of the pipe opening of the DC+ liquid-cooled terminal 7 and the DC+ liquid-cooled electrode 6 respectively.

[0048] A liquid inlet 61 and a liquid outlet 62 are provided in the DC+ liquid-cooled electrode 6, and a cooling cavity 71 is provided in the DC+ liquid-cooled terminal 7. One end of the insulating jacket 23 in the DC+ liquid-cooled charging cable 2 is sleeved on the pipe mouth of the DC+ liquid-cooled electrode 6, and the other end is sleeved on the pipe mouth of the DC+ liquid-cooled terminal 7. One end of the DC+ cooling liquid channel 21 in a DC+ liquid-cooled charging cable 2 is connected to the liquid inlet 61, and the other end is connected to the cooling cavity 71; one end of the DC+ cooling liquid channel 21 in another DC+ liquid-cooled charging cable 2 is connected to the liquid outlet 62, and the other end is connected to the cooling cavity 71. In this way, the DC+ cooling liquid channels 21 in the two DC+ liquid-cooled charging cables 2 are connected through the cooling cavity 71, and the coolant enters one of the DC+ cooling liquid channels 21 from the liquid inlet 61, and then flows into the other DC+ cooling liquid channel 21 through the cooling cavity 71, and finally flows out from the liquid outlet 62, forming a cooling circuit.

[0049] See attached Figure 5. Similarly, the DC-liquid-cooled charging cable 3 is also composed of an insulating jacket and a DC-conductor 32, and the annular channel between the insulating jacket and the DC-conductor 32 is a DC-cooling liquid channel 31 for the circulation of coolant. Two DC-liquid-cooled charging cables 3 are connected between the DC-liquid-cooled terminal 9 and the DC-liquid-cooled electrode 8, wherein two DC-conductors 32 are connected in parallel between the DC-liquid-cooled terminal 9 and the DC-liquid-cooled electrode 8 for jointly carrying the charging current. In this embodiment, the two ends of the DC-conductor 32 are respectively crimped onto the inner walls of the pipe orifices of the DC-liquid-cooled terminal 9 and the DC-liquid-cooled electrode 8.

[0050] A liquid inlet 81 and a liquid outlet 82 are provided in the DC-liquid-cooled electrode 8, and a cooling cavity 91 is provided in the DC-liquid-cooled terminal 9. One end of the insulating jacket in the DC-liquid-cooled charging cable 3 is sleeved on the pipe mouth of the DC-liquid-cooled electrode 8, and the other end is sleeved on the pipe mouth of the DC-liquid-cooled terminal 9. The DC-cooling liquid channel 31 in one DC-liquid-cooled charging cable 3 is connected to the liquid inlet 81 at one end, and to the cooling cavity 91 at the other end; the DC-cooling liquid channel 31 in another DC-liquid-cooled charging cable 3 is connected to the liquid outlet 82 at one end, and to the cooling cavity 91 at the other end. In this way, the DC-cooling liquid channels 31 in the two DC-liquid-cooled charging cables 3 are connected through the cooling cavity 91, and the coolant enters one of the DC-cooling liquid channels 31 from the liquid inlet 81, and then flows into the other DC-cooling liquid channel 31 through the cooling cavity 91, and finally flows out from the liquid outlet 82, forming a cooling circuit.

[0051] Since the DC+ liquid-cooled charging cable 2 and the DC- liquid-cooled charging cable 3 have their own independent cooling circuits, after the liquid cooler is turned on, the coolant can circulate and cool the DC+ wire 22 and the DC- wire 32, and take away the heat generated by the DC+ wire 22 and the DC- wire 32 due to conduction. Practice has proved that when safely carrying 800A current, the wire diameter of this liquid-cooled integrated cable is only 26mm. In addition, this liquid-cooled integrated cable is relatively soft, with a bending radius of less than 200mm.

[0052] Continue to refer to the attached Figure 2 Among the twenty auxiliary wires 5, four are temperature data transmission wires, namely T1+ wire, T1- wire, T2+ wire and T2- wire; four are electronic lock connection wires, namely PIN1 wire, PIN2 wire, EL+ wire and EL- wire; four are shielding wires, namely CC1 wire, CC2 wire, S+ wire and S- wire; the remaining eight auxiliary wires 5, four are connected in parallel to form an A+ auxiliary power line, and four are connected in parallel to form an A- auxiliary power line.

[0053] The A+ auxiliary power line and the A- auxiliary power line are designed to carry the largest current, in addition to the charging line and the ground line 4. The function of the A+ auxiliary power line and the A- auxiliary power line is to provide low-voltage DC power to the charging gun to ensure the normal operation of the sensors and electronic locks in the charging gun. Connecting four wires in parallel into one A+ auxiliary power line and four wires in parallel into one A- auxiliary power line can improve the rationality of the overall cable layout while ensuring the carrying current.

[0054] To further improve the technical solution, a wrapping tape is provided between the insulating outer jacket 1 and the DC+ liquid-cooled charging cable 2, the DC- liquid-cooled charging cable 3, and the auxiliary cable 5. The wrapping tape is wound with a non-woven tape or a metal foil tape. By winding the wrapping tape, the DC+ liquid-cooled charging cable 2, the DC- liquid-cooled charging cable 3, and the auxiliary cable 5 can be shaped and protected. Embodiment 2:

[0055] See attached Figure 6 Different from the first embodiment, in the present embodiment, four gaps between the DC+ liquid-cooled charging cable 2 , the DC- liquid-cooled charging cable 3 and the insulating outer jacket 1 are respectively filled with a filling rope 10 .

[0056] The filling rope 10 can be made of PP material or glass fiber material. The filling rope 10 has two functions: first, the filling rope 10 is used as a filler to fill the gap, which is beneficial to improve the roundness of the cable; second, the filling rope 10 can improve the tensile strength of the entire cable.

[0057] It should be noted that this liquid-cooled integrated cable is applicable to the GB20234.3-2015 DC charging gun standard, the HPC super charging gun standard, the IEC 62196-3 American charging gun standard, the IEC 62196-3 European charging gun standard, and the IEC 62196-3 Japanese charging gun standard.

[0058] Although the embodiments of the present invention have been shown and described, it is understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the protection scope of the present invention is defined by the attached claims and their equivalents.

Claims

1. A liquid-cooled integrated cable for an 800A charging gun, wherein a DC+ liquid-cooled charging line, a DC- liquid-cooled charging line, a grounding line and several auxiliary lines are wrapped in its insulating outer sheath, wherein: A DC+ cooling liquid channel and a DC+ conductor are provided in the DC+ liquid-cooled charging cable, and the DC+ cooling liquid channel and the DC+ conductor are connected between the DC+ liquid-cooled terminal and the DC+ liquid-cooled electrode. A DC- cooling liquid channel and a DC- conductor are provided in the DC- liquid-cooled charging cable, and the DC- cooling liquid channel and the DC- conductor are connected between the DC- liquid-cooled terminal and the DC- liquid-cooled electrode. The invention is characterized in that: there are two DC+ liquid-cooled charging cables and two DC- liquid-cooled charging cables, and the DC+ cooling liquid channels in the two DC+ liquid-cooled charging cables are connected in the DC+ liquid-cooled terminal to form a cooling circuit; the DC- cooling liquid channels in the two DC- liquid-cooled charging cables are connected in the DC- liquid-cooled terminal to form a cooling circuit.

2. The liquid-cooled integrated cable for an 800A charging gun according to claim 1, characterized in that: Observing the cross-section of the liquid-cooled integrated cable, there is one grounding wire, which is located in the center of the liquid-cooled integrated cable; two DC+ liquid-cooled charging wires and two DC- liquid-cooled charging wires are closely arranged circumferentially with the grounding wire as the center; the auxiliary wires are evenly filled in the gaps between the DC+ liquid-cooled charging wire, DC- liquid-cooled charging wire and the insulating outer sheath.

3. The liquid-cooled integrated cable for an 800A charging gun as claimed in claim 2, characterized in that: The wire diameter of the DC+ liquid-cooled charging cable is equal to the wire diameter of the DC- liquid-cooled charging cable, and the wire diameters of each auxiliary line are the same.

4. The liquid-cooled integrated cable for an 800A charging gun as claimed in claim 3, characterized in that: The ratio of the ground wire diameter to the DC+ liquid-cooled charging wire diameter is 0.

414.

5. The liquid-cooled integrated cable for an 800A charging gun as claimed in claim 2, characterized in that: There are twenty auxiliary wires, and the twenty auxiliary wires are grouped into five and evenly filled in the gaps between the DC+ liquid-cooled charging wire, the DC- liquid-cooled charging wire and the insulating outer sheath.

6. The liquid-cooled integrated cable for an 800A charging gun as claimed in claim 5, characterized in that: Among the twenty auxiliary wires, four are temperature data transmission wires, namely T1+ wire, T1- wire, T2+ wire and T2- wire; four are electronic lock connection wires, namely PIN1 wire, PIN2 wire, EL+ wire and EL- wire; four are shielding wires, namely CC1 wire, CC2 wire, S+ wire and S- wire; of the remaining eight auxiliary wires, four are connected in parallel to form an A+ auxiliary power line, and four are connected in parallel to form an A- auxiliary power line.

7. The liquid-cooled integrated cable for an 800A charging gun as claimed in claim 2, characterized in that: A wrapping tape is provided between the insulating outer sheath and the DC+ liquid-cooled charging cable, the DC- liquid-cooled charging cable, and the auxiliary cable, and the wrapping tape is formed by winding a non-woven fabric tape or a metal foil tape.

8. The liquid-cooled integrated cable for an 800A charging gun as claimed in claim 2, characterized in that: The gaps between the DC+ liquid-cooled charging cable, the DC- liquid-cooled charging cable and the insulating outer sheath are filled with filling ropes.

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