DC Charging Gun Cooling System for High Current Thermal Management
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Solution Overview
Problem
High temperatures at the joints between cables and terminals in direct-current charging guns reduce charging efficiency and pose a risk of damage or fire, especially when charging currents range from 500 A to 600 A.
Innovation Solution
A charging gun cooling system with a head cooling assembly, liquid inlet and outlet pipes, and heat conductive members that direct heat away from the terminals, using a coolant to absorb and dissipate heat, and a tail cooling assembly to manage heat at connection boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If charging current is increased to improve charging speed, then charging efficiency is improved, but temperature at joints increases causing reduced efficiency and safety risks
Solution Approach 1:
A cooling cavity filled with coolant is introduced as an intermediary substance between the heat-generating joints and the surrounding environment. The coolant absorbs heat from the joints through thermal conduction and convection, effectively reducing joint temperature while allowing high charging currents to maintain high charging speed
Solution Approach 2:
The patent employs a liquid cooling system where coolant flows through the cooling cavity via hydraulic principles. The liquid coolant circulates continuously, absorbing heat at the joints and transporting it away, thereby maintaining low joint temperatures even at high charging currents of 500-600A
2Loss of time
If charging current is increased to shorten charging time, then user experience is improved, but heat generation at joints increases reducing efficiency
Solution Approach 1:
The coolant acts as an intermediary heat transfer medium that prevents energy loss at the joints. By continuously removing heat generated during high-current charging, the cooling system ensures that electrical energy is efficiently converted to chemical energy in the battery rather than being wasted as heat, thus maintaining high charging efficiency while reducing charging time
3Productivity
If charging current is increased to improve charging speed, then charging performance is improved, but safety risks increase due to overheating
Solution Approach 1:
The cooling cavity with circulating coolant serves as a safety intermediary that actively manages thermal risks. The coolant continuously absorbs heat from the joints, preventing temperature from reaching dangerous levels that could cause fire or damage, thereby enabling high-speed charging to proceed safely
Solution Approach 2:
The cooling system provides beforehand cushioning by preemptively removing heat before it can accumulate to dangerous levels. The continuous circulation of coolant creates a thermal buffer that protects the charging gun components from overheating, ensuring safety is maintained even during high-current operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively reduces temperatures at critical joints, enhancing charging efficiency and safety by preventing overheating and potential fires.
Implementation Method 1
a cooling cavity 12 disposed in the support frame 11 and between the first terminal 100 and the second terminal 200
Implementation Method 2
using a coolant to absorb and dissipate heat
Data Source
AI summary
Provided are a charging gun cooling system and a charging gun, relating to the technical field of charging guns. In the charging gun cooling system, a head cooling assembly includes a support frame and a cooling cavity, the cooling cavity is provided with a liquid inlet and a liquid outlet, the support frame is configured to accommodate a connection end of a first terminal and a connection end of a second terminal, the cooling cavity is disposed in the support frame and between the first terminal and the second terminal, a liquid inlet pipe communicates with the liquid inlet, a liquid outlet pipe communicates with the liquid outlet, a first cable is laid on the outer surface of the liquid inlet pipe, and a second cable is laid on the outer surface of the liquid outlet pipe.