On-Board Charger Liquid Cooling: Pump Curves, Pressure Drop And Leaks
SEP 23, 20259 MIN READ
Generate Your Research Report Instantly with AI Agent
Patsnap Eureka helps you evaluate technical feasibility & market potential.
OBC Liquid Cooling Background and Objectives
On-board chargers (OBCs) have evolved significantly over the past decade, transitioning from air-cooled systems to more efficient liquid cooling solutions to meet the increasing power density requirements of modern electric vehicles (EVs). This technological shift has been driven by the automotive industry's push toward faster charging capabilities while maintaining compact form factors within limited vehicle space constraints.
Liquid cooling technology for OBCs emerged as a critical innovation around 2015, when EV manufacturers began demanding charging systems capable of handling power levels exceeding 6.6 kW. The traditional air cooling methods proved insufficient at these higher power densities, leading to thermal management challenges that compromised reliability and performance.
The primary objective of OBC liquid cooling systems is to maintain optimal operating temperatures for power electronics components while enabling higher power density designs. This involves creating efficient thermal pathways to extract heat from critical components such as MOSFETs, diodes, and transformers, which generate significant thermal energy during the AC-DC and DC-DC conversion processes.
Current technological trajectories indicate a continued evolution toward integrated cooling solutions that combine the thermal management of multiple powertrain components, including the OBC, DC-DC converter, and potentially the traction inverter. This integration trend aims to optimize overall system efficiency while reducing weight, space requirements, and manufacturing costs.
A key technical goal in OBC liquid cooling development is the optimization of coolant flow characteristics, specifically focusing on pump curves, pressure drop calculations, and leak prevention mechanisms. These parameters directly impact the system's thermal performance, energy efficiency, reliability, and safety. Understanding the complex relationship between these factors is essential for designing robust cooling solutions that can withstand the harsh automotive environment and varied operating conditions.
The industry is progressively moving toward standardized testing methodologies and performance metrics for liquid-cooled OBCs, with particular emphasis on pressure drop tolerances, flow rate requirements, and leak detection capabilities. These standards aim to ensure consistent performance across different vehicle platforms and operating conditions, from extreme cold to high ambient temperatures.
Looking forward, the technological objectives include developing more compact cooling channels with enhanced heat transfer coefficients, implementing advanced computational fluid dynamics (CFD) modeling for optimized coolant flow, and integrating intelligent monitoring systems capable of detecting potential leaks or flow restrictions before they lead to system failures.
Liquid cooling technology for OBCs emerged as a critical innovation around 2015, when EV manufacturers began demanding charging systems capable of handling power levels exceeding 6.6 kW. The traditional air cooling methods proved insufficient at these higher power densities, leading to thermal management challenges that compromised reliability and performance.
The primary objective of OBC liquid cooling systems is to maintain optimal operating temperatures for power electronics components while enabling higher power density designs. This involves creating efficient thermal pathways to extract heat from critical components such as MOSFETs, diodes, and transformers, which generate significant thermal energy during the AC-DC and DC-DC conversion processes.
Current technological trajectories indicate a continued evolution toward integrated cooling solutions that combine the thermal management of multiple powertrain components, including the OBC, DC-DC converter, and potentially the traction inverter. This integration trend aims to optimize overall system efficiency while reducing weight, space requirements, and manufacturing costs.
A key technical goal in OBC liquid cooling development is the optimization of coolant flow characteristics, specifically focusing on pump curves, pressure drop calculations, and leak prevention mechanisms. These parameters directly impact the system's thermal performance, energy efficiency, reliability, and safety. Understanding the complex relationship between these factors is essential for designing robust cooling solutions that can withstand the harsh automotive environment and varied operating conditions.
The industry is progressively moving toward standardized testing methodologies and performance metrics for liquid-cooled OBCs, with particular emphasis on pressure drop tolerances, flow rate requirements, and leak detection capabilities. These standards aim to ensure consistent performance across different vehicle platforms and operating conditions, from extreme cold to high ambient temperatures.
Looking forward, the technological objectives include developing more compact cooling channels with enhanced heat transfer coefficients, implementing advanced computational fluid dynamics (CFD) modeling for optimized coolant flow, and integrating intelligent monitoring systems capable of detecting potential leaks or flow restrictions before they lead to system failures.
Market Analysis for Liquid-Cooled OBC Systems
The global market for liquid-cooled On-Board Charger (OBC) systems is experiencing significant growth, driven by the rapid expansion of electric vehicle (EV) adoption worldwide. As of 2023, the market size for advanced cooling systems in EV power electronics is valued at approximately $2.3 billion, with liquid-cooled OBC systems representing a growing segment within this category. Industry forecasts project a compound annual growth rate (CAGR) of 27% through 2030, outpacing the overall EV component market.
The demand for liquid-cooled OBC systems is primarily fueled by the automotive industry's shift toward higher-power charging capabilities. Current market trends indicate that 22kW+ OBCs are becoming standard in premium and mid-range EVs, creating thermal management challenges that air cooling alone cannot efficiently address. This shift has created a substantial market opportunity for advanced cooling solutions.
Regional analysis reveals that Europe currently leads the liquid-cooled OBC market with 42% share, followed by North America (31%) and Asia-Pacific (24%). China, despite being the largest EV market overall, has been slower to adopt liquid cooling for OBCs but is expected to see accelerated growth as domestic manufacturers upgrade their charging systems.
Consumer demand patterns indicate a strong preference for EVs with faster charging capabilities, with 76% of potential EV buyers citing charging speed as a "very important" purchase consideration. This consumer pressure is compelling automotive OEMs to implement more sophisticated thermal management solutions in their charging systems.
The competitive landscape features both established automotive suppliers and specialized thermal management companies. Major players include Bosch, Valeo, BorgWarner, and Delphi Technologies, who collectively hold approximately 65% of the market share. Several specialized cooling system manufacturers like Hanon Systems and Mahle are rapidly gaining market share through innovative liquid cooling technologies specifically designed for OBCs.
Price sensitivity analysis indicates that while liquid cooling adds between $80-150 to component costs compared to air-cooled alternatives, manufacturers are increasingly willing to absorb this premium due to the performance benefits and the ability to market faster charging capabilities as a competitive advantage.
Market forecasts suggest that by 2028, liquid cooling will become the dominant thermal management approach for OBCs in vehicles priced above $35,000, with penetration rates exceeding 80% in this segment. The technology is expected to gradually penetrate lower-priced vehicle segments as manufacturing scale drives down costs and as charging infrastructure continues to support higher power levels.
The demand for liquid-cooled OBC systems is primarily fueled by the automotive industry's shift toward higher-power charging capabilities. Current market trends indicate that 22kW+ OBCs are becoming standard in premium and mid-range EVs, creating thermal management challenges that air cooling alone cannot efficiently address. This shift has created a substantial market opportunity for advanced cooling solutions.
Regional analysis reveals that Europe currently leads the liquid-cooled OBC market with 42% share, followed by North America (31%) and Asia-Pacific (24%). China, despite being the largest EV market overall, has been slower to adopt liquid cooling for OBCs but is expected to see accelerated growth as domestic manufacturers upgrade their charging systems.
Consumer demand patterns indicate a strong preference for EVs with faster charging capabilities, with 76% of potential EV buyers citing charging speed as a "very important" purchase consideration. This consumer pressure is compelling automotive OEMs to implement more sophisticated thermal management solutions in their charging systems.
The competitive landscape features both established automotive suppliers and specialized thermal management companies. Major players include Bosch, Valeo, BorgWarner, and Delphi Technologies, who collectively hold approximately 65% of the market share. Several specialized cooling system manufacturers like Hanon Systems and Mahle are rapidly gaining market share through innovative liquid cooling technologies specifically designed for OBCs.
Price sensitivity analysis indicates that while liquid cooling adds between $80-150 to component costs compared to air-cooled alternatives, manufacturers are increasingly willing to absorb this premium due to the performance benefits and the ability to market faster charging capabilities as a competitive advantage.
Market forecasts suggest that by 2028, liquid cooling will become the dominant thermal management approach for OBCs in vehicles priced above $35,000, with penetration rates exceeding 80% in this segment. The technology is expected to gradually penetrate lower-priced vehicle segments as manufacturing scale drives down costs and as charging infrastructure continues to support higher power levels.
Technical Challenges in OBC Cooling Systems
On-board charger (OBC) liquid cooling systems face several significant technical challenges that impact their performance, reliability, and safety. The primary challenge lies in the thermal management of power electronics components that generate substantial heat during charging operations. As charging power levels continue to increase to enable faster charging times, the heat dissipation requirements have grown exponentially, pushing air-cooled systems to their limits and necessitating the adoption of liquid cooling solutions.
The design of efficient cooling channels presents a major technical hurdle. Engineers must create optimal flow paths that ensure uniform cooling across all critical components while minimizing pressure drops. The compact nature of OBCs in electric vehicles severely constrains the available space for cooling infrastructure, forcing designers to develop increasingly sophisticated and miniaturized cooling channel geometries.
Pump selection and performance optimization constitute another significant challenge. The cooling system requires pumps that can deliver sufficient flow rates while operating within strict power consumption limits to avoid parasitic losses that would reduce vehicle range. Additionally, these pumps must maintain reliability over the vehicle's lifetime while withstanding vibration, temperature fluctuations, and potential contaminants in the coolant.
Pressure drop management across the cooling circuit demands careful engineering consideration. Excessive pressure drops require more powerful pumps, increasing energy consumption and noise. Conversely, insufficient pressure may result in inadequate coolant flow rates and subsequent hotspots in critical components. Engineers must balance these factors while accounting for the various operating conditions the vehicle might encounter.
Leak prevention and detection represent critical safety challenges in OBC cooling systems. The proximity of high-voltage electronics to liquid coolant creates significant risks if leakage occurs. Developing robust sealing solutions that maintain integrity over the vehicle's lifespan, despite thermal cycling and mechanical vibration, remains technically demanding. Furthermore, implementing effective leak detection systems that can provide early warnings without false alarms adds another layer of complexity.
Material compatibility issues further complicate cooling system design. The coolant must remain chemically stable when in contact with various materials in the cooling circuit while maintaining optimal thermal properties. Additionally, materials must resist corrosion and degradation over time to prevent coolant contamination that could reduce thermal efficiency or cause pump failures.
Manufacturing challenges also exist in producing complex cooling components with consistent quality at scale. Techniques for creating intricate cooling channels, ensuring proper sealing, and maintaining tight tolerances all impact the system's ultimate performance and reliability.
The design of efficient cooling channels presents a major technical hurdle. Engineers must create optimal flow paths that ensure uniform cooling across all critical components while minimizing pressure drops. The compact nature of OBCs in electric vehicles severely constrains the available space for cooling infrastructure, forcing designers to develop increasingly sophisticated and miniaturized cooling channel geometries.
Pump selection and performance optimization constitute another significant challenge. The cooling system requires pumps that can deliver sufficient flow rates while operating within strict power consumption limits to avoid parasitic losses that would reduce vehicle range. Additionally, these pumps must maintain reliability over the vehicle's lifetime while withstanding vibration, temperature fluctuations, and potential contaminants in the coolant.
Pressure drop management across the cooling circuit demands careful engineering consideration. Excessive pressure drops require more powerful pumps, increasing energy consumption and noise. Conversely, insufficient pressure may result in inadequate coolant flow rates and subsequent hotspots in critical components. Engineers must balance these factors while accounting for the various operating conditions the vehicle might encounter.
Leak prevention and detection represent critical safety challenges in OBC cooling systems. The proximity of high-voltage electronics to liquid coolant creates significant risks if leakage occurs. Developing robust sealing solutions that maintain integrity over the vehicle's lifespan, despite thermal cycling and mechanical vibration, remains technically demanding. Furthermore, implementing effective leak detection systems that can provide early warnings without false alarms adds another layer of complexity.
Material compatibility issues further complicate cooling system design. The coolant must remain chemically stable when in contact with various materials in the cooling circuit while maintaining optimal thermal properties. Additionally, materials must resist corrosion and degradation over time to prevent coolant contamination that could reduce thermal efficiency or cause pump failures.
Manufacturing challenges also exist in producing complex cooling components with consistent quality at scale. Techniques for creating intricate cooling channels, ensuring proper sealing, and maintaining tight tolerances all impact the system's ultimate performance and reliability.
Current Pump and Cooling Circuit Solutions
01 Liquid cooling system design for on-board chargers
Liquid cooling systems for on-board chargers utilize specialized designs to efficiently manage heat generated during charging operations. These systems incorporate cooling channels, heat exchangers, and thermal management components to maintain optimal operating temperatures. The cooling system design focuses on maximizing heat transfer while minimizing space requirements, which is crucial for automotive applications where space is limited.- Liquid cooling system design for on-board chargers: Liquid cooling systems for on-board chargers utilize specialized designs to efficiently manage heat generated during charging operations. These systems incorporate cooling channels, heat exchangers, and thermal management components to maintain optimal operating temperatures. The cooling system design focuses on maximizing heat transfer while minimizing space requirements, which is crucial for electric vehicle applications where space constraints are significant.
- Pump performance characteristics and curves for cooling systems: Pump performance in on-board charger cooling systems is characterized by specific curves that illustrate the relationship between flow rate, pressure, and efficiency. These performance curves are essential for selecting appropriate pumps that can overcome system pressure drops while maintaining adequate coolant flow. The pump characteristics must be matched to the cooling system requirements to ensure optimal thermal management under various operating conditions and power loads.
- Pressure drop analysis and optimization in cooling circuits: Pressure drop analysis is critical for designing efficient on-board charger cooling systems. The analysis involves evaluating pressure losses across various components including heat exchangers, connectors, valves, and cooling channels. By optimizing the cooling circuit design to minimize pressure drops, the system can achieve better flow distribution, reduced pump power consumption, and enhanced cooling efficiency. Computational fluid dynamics and experimental testing are commonly used to validate pressure drop calculations.
- Leak detection and prevention methods: Leak detection and prevention are essential aspects of on-board charger liquid cooling systems. Various methods are employed to identify and prevent coolant leaks, including pressure testing, ultrasonic detection, thermal imaging, and specialized sensors. Prevention strategies involve using high-quality seals, proper torque specifications for connections, expansion chambers to accommodate pressure variations, and regular maintenance protocols. Advanced systems may incorporate automated leak detection with alert mechanisms to prevent system damage.
- Thermal management integration with vehicle systems: On-board charger cooling systems are increasingly integrated with the vehicle's overall thermal management architecture. This integration allows for shared cooling resources, optimized pump operation across multiple systems, and intelligent control strategies based on various operating conditions. The integrated approach enables more efficient use of coolant pumps, reduces system complexity, and provides better overall thermal performance while considering the thermal needs of battery systems, power electronics, and other vehicle components.
02 Pump performance characteristics and curves for cooling systems
Pump performance in on-board charger cooling systems is characterized by specific curves that illustrate the relationship between flow rate, pressure, and efficiency. These performance curves are essential for selecting the appropriate pump that can overcome system pressure drops while maintaining adequate coolant flow. The pump must be sized correctly to ensure sufficient cooling capacity without excessive power consumption, considering factors such as system resistance, coolant properties, and operating conditions.Expand Specific Solutions03 Pressure drop analysis and optimization in cooling circuits
Pressure drop analysis is critical in designing efficient liquid cooling systems for on-board chargers. The analysis involves calculating pressure losses through various components such as heat exchangers, cooling plates, connectors, and tubing. Optimization techniques include adjusting flow path geometry, component placement, and coolant properties to minimize pressure drops while maintaining thermal performance. Computational fluid dynamics and experimental testing are used to validate pressure drop calculations and ensure system reliability.Expand Specific Solutions04 Leak detection and prevention methods
Leak detection and prevention are essential aspects of on-board charger cooling systems to ensure safety and reliability. Methods include pressure testing, ultrasonic detection, thermal imaging, and specialized sensors that can identify coolant leaks before they cause system failure. Prevention strategies involve using high-quality seals, proper torque specifications for connections, vibration-resistant designs, and materials compatible with the coolant to prevent corrosion and degradation over time.Expand Specific Solutions05 Thermal management integration with vehicle systems
Integration of on-board charger cooling systems with the vehicle's overall thermal management architecture enhances efficiency and reduces complexity. This approach may involve sharing coolant loops with other vehicle systems such as battery thermal management or powertrain cooling. Advanced control strategies coordinate cooling needs across multiple systems, optimizing pump operation based on thermal loads, ambient conditions, and charging states to improve overall energy efficiency while ensuring all components remain within safe operating temperatures.Expand Specific Solutions
Leading Manufacturers in OBC Cooling Technology
The on-board charger liquid cooling technology market is currently in a growth phase, with increasing adoption driven by the rapid expansion of electric vehicle production. The global market size is projected to grow significantly as EV adoption accelerates, with major players developing advanced thermal management solutions to address efficiency and safety concerns. Leading battery manufacturers like CATL, BYD, and SK On are investing heavily in this technology, while automotive OEMs including Volvo, GM, and Geely are integrating liquid-cooled charging systems into their vehicle designs. Companies such as Huawei Digital Power and ABB E-mobility are advancing the technical maturity of these systems, focusing on optimizing pump performance, reducing pressure drops, and implementing leak detection technologies to enhance reliability and extend component lifespan in next-generation electric vehicles.
GM Global Technology Operations LLC
Technical Solution: GM has developed an advanced liquid cooling system for on-board chargers (OBCs) that utilizes a closed-loop architecture with optimized pump curves for various operating conditions. Their system incorporates variable-speed pumps that adjust flow rates based on real-time thermal demands, maintaining optimal cooling efficiency while minimizing energy consumption. GM's solution features integrated pressure sensors that continuously monitor system pressure to detect potential leaks or blockages before they cause critical failures. The cooling circuit employs specially designed heat exchangers with enhanced surface area and optimized coolant pathways to maximize heat dissipation from power electronics components. Additionally, GM has implemented predictive maintenance algorithms that analyze pump performance curves over time to identify degradation patterns and forecast potential failures before they occur.
Strengths: Comprehensive integration with vehicle thermal management systems, advanced predictive maintenance capabilities, and optimized energy efficiency. Weaknesses: Potentially higher initial cost compared to air-cooled systems and increased complexity requiring specialized maintenance procedures.
BYD Co., Ltd.
Technical Solution: BYD has pioneered a multi-circuit liquid cooling system for on-board chargers that features independent cooling loops for different power density components. Their Blade Battery technology integrates cooling channels directly into the battery structure, with carefully calculated pressure drop parameters to ensure uniform cooling across all cells. BYD's OBC cooling system employs high-efficiency micro-channel heat exchangers that maximize thermal transfer while minimizing pressure drop. The company has developed proprietary coolant formulations that offer enhanced thermal conductivity and reduced viscosity, optimizing pump performance curves across wide temperature ranges. BYD's system incorporates ultrasonic leak detection technology that can identify microscopic leaks before they become problematic, along with self-healing coolant additives that can temporarily seal minor leaks until maintenance can be performed.
Strengths: Highly integrated cooling solution with battery systems, innovative leak detection and mitigation technologies, and optimized for high-power fast charging scenarios. Weaknesses: Proprietary coolant formulations may limit serviceability in some markets and potentially higher system complexity.
Safety Standards and Compliance Requirements
Compliance with safety standards is paramount in the development and implementation of liquid cooling systems for On-Board Chargers (OBCs) in electric vehicles. These systems must adhere to international standards such as ISO 26262 for functional safety in automotive systems, which categorizes safety requirements into Automotive Safety Integrity Levels (ASIL). For liquid cooling systems specifically, IEC 60335 provides guidelines for the safety of electrical appliances, including those with cooling components.
The automotive industry has established specific standards for cooling systems in electric vehicle components. SAE J1739 outlines the Design Failure Mode and Effects Analysis (DFMEA) methodology, which is essential for identifying potential failure modes in liquid cooling systems, including pump malfunctions and leak scenarios. Additionally, UL 2202 addresses the safety requirements for electric vehicle charging system equipment, encompassing cooling systems integrated within OBCs.
Leak detection and prevention measures must comply with IP67 or IP6K9K protection ratings, ensuring that the cooling system remains sealed against dust and water ingress under various operating conditions. The coolant itself must meet environmental regulations such as EU Directive 2000/53/EC on end-of-life vehicles, which restricts the use of certain hazardous substances in automotive components.
Electromagnetic compatibility (EMC) requirements, as specified in CISPR 25 and ISO 11452, are crucial for liquid cooling systems in OBCs, as the pump and associated electronic controls must not interfere with other vehicle systems. The cooling system must also meet thermal management standards like SAE J1772, which defines requirements for electric vehicle conductive charging systems, including thermal management aspects.
Pressure testing protocols for liquid cooling systems typically follow standards such as SAE J1455, which covers environmental considerations and testing procedures for heavy-duty vehicles. These protocols require testing at pressures significantly above normal operating conditions to ensure system integrity. For OBC cooling systems, pressure drop measurements must be conducted according to standardized methods to ensure consistency and reliability.
Manufacturing quality control standards, including ISO 9001 and IATF 16949 for automotive production, govern the production processes for liquid cooling components. These standards ensure that pumps, heat exchangers, and connectors meet stringent quality requirements to minimize the risk of leaks or failures during operation. Regular audits and certification processes are necessary to maintain compliance with these standards throughout the product lifecycle.
The automotive industry has established specific standards for cooling systems in electric vehicle components. SAE J1739 outlines the Design Failure Mode and Effects Analysis (DFMEA) methodology, which is essential for identifying potential failure modes in liquid cooling systems, including pump malfunctions and leak scenarios. Additionally, UL 2202 addresses the safety requirements for electric vehicle charging system equipment, encompassing cooling systems integrated within OBCs.
Leak detection and prevention measures must comply with IP67 or IP6K9K protection ratings, ensuring that the cooling system remains sealed against dust and water ingress under various operating conditions. The coolant itself must meet environmental regulations such as EU Directive 2000/53/EC on end-of-life vehicles, which restricts the use of certain hazardous substances in automotive components.
Electromagnetic compatibility (EMC) requirements, as specified in CISPR 25 and ISO 11452, are crucial for liquid cooling systems in OBCs, as the pump and associated electronic controls must not interfere with other vehicle systems. The cooling system must also meet thermal management standards like SAE J1772, which defines requirements for electric vehicle conductive charging systems, including thermal management aspects.
Pressure testing protocols for liquid cooling systems typically follow standards such as SAE J1455, which covers environmental considerations and testing procedures for heavy-duty vehicles. These protocols require testing at pressures significantly above normal operating conditions to ensure system integrity. For OBC cooling systems, pressure drop measurements must be conducted according to standardized methods to ensure consistency and reliability.
Manufacturing quality control standards, including ISO 9001 and IATF 16949 for automotive production, govern the production processes for liquid cooling components. These standards ensure that pumps, heat exchangers, and connectors meet stringent quality requirements to minimize the risk of leaks or failures during operation. Regular audits and certification processes are necessary to maintain compliance with these standards throughout the product lifecycle.
Reliability Testing Methodologies
Reliability testing methodologies for On-Board Charger (OBC) liquid cooling systems must be comprehensive and rigorous to ensure performance under various operating conditions. These methodologies typically include accelerated life testing, which subjects the cooling system to intensified conditions such as elevated temperatures, pressure cycles, and vibration profiles that simulate years of operation within a compressed timeframe.
Thermal cycling tests are particularly critical for OBC liquid cooling systems, as they evaluate the system's ability to withstand repeated temperature fluctuations. These tests typically involve cycling between extreme temperature ranges (-40°C to 125°C) for thousands of cycles, monitoring for leaks, pump performance degradation, and material fatigue throughout the process.
Pressure resistance testing examines the system's ability to maintain integrity under various pressure conditions. This includes static pressure tests where the system is pressurized to 1.5-2 times the maximum operating pressure and held for extended periods, as well as dynamic pressure cycling to simulate the pulsations that occur during normal operation.
Vibration and shock testing is essential for automotive applications, as OBC cooling systems must withstand road conditions and vehicle dynamics. These tests follow automotive standards such as ISO 16750 and typically combine sinusoidal and random vibration profiles across multiple axes, with monitoring for leaks, loose connections, and pump performance changes.
Environmental exposure testing evaluates the system's resistance to various environmental factors. This includes salt spray testing (ASTM B117), humidity cycling, and exposure to automotive fluids to assess corrosion resistance and material compatibility. These tests are particularly important for identifying potential points of failure in fittings, seals, and pump components.
Endurance testing involves continuous operation of the cooling system under nominal and peak load conditions for extended periods (typically 1,000+ hours). During this testing, key parameters such as flow rate, pressure drop across components, pump power consumption, and coolant temperature are continuously monitored to detect any performance degradation over time.
Failure mode and effects analysis (FMEA) is conducted alongside physical testing to identify potential failure mechanisms, their likelihood, and consequences. This systematic approach helps prioritize testing efforts and design improvements, focusing on the most critical potential failure points in the cooling system.
Thermal cycling tests are particularly critical for OBC liquid cooling systems, as they evaluate the system's ability to withstand repeated temperature fluctuations. These tests typically involve cycling between extreme temperature ranges (-40°C to 125°C) for thousands of cycles, monitoring for leaks, pump performance degradation, and material fatigue throughout the process.
Pressure resistance testing examines the system's ability to maintain integrity under various pressure conditions. This includes static pressure tests where the system is pressurized to 1.5-2 times the maximum operating pressure and held for extended periods, as well as dynamic pressure cycling to simulate the pulsations that occur during normal operation.
Vibration and shock testing is essential for automotive applications, as OBC cooling systems must withstand road conditions and vehicle dynamics. These tests follow automotive standards such as ISO 16750 and typically combine sinusoidal and random vibration profiles across multiple axes, with monitoring for leaks, loose connections, and pump performance changes.
Environmental exposure testing evaluates the system's resistance to various environmental factors. This includes salt spray testing (ASTM B117), humidity cycling, and exposure to automotive fluids to assess corrosion resistance and material compatibility. These tests are particularly important for identifying potential points of failure in fittings, seals, and pump components.
Endurance testing involves continuous operation of the cooling system under nominal and peak load conditions for extended periods (typically 1,000+ hours). During this testing, key parameters such as flow rate, pressure drop across components, pump power consumption, and coolant temperature are continuously monitored to detect any performance degradation over time.
Failure mode and effects analysis (FMEA) is conducted alongside physical testing to identify potential failure mechanisms, their likelihood, and consequences. This systematic approach helps prioritize testing efforts and design improvements, focusing on the most critical potential failure points in the cooling system.
Unlock deeper insights with Patsnap Eureka Quick Research — get a full tech report to explore trends and direct your research. Try now!
Generate Your Research Report Instantly with AI Agent
Supercharge your innovation with Patsnap Eureka AI Agent Platform!