Liquid-Cooled Charging Pile for Safe Ultra-Fast EV Charging
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Solution Overview
Problem
As charging power increases in electric vehicles, heat generation also rises, leading to potential efficiency and safety issues if not timely dissipated, affecting normal high-power charging.
Innovation Solution
A charging pile with a liquid cooling device and heat exchanger system that delivers coolant to the electric vehicle to absorb heat, ensuring timely heat dissipation and only initiating charging when coolant delivery is confirmed, with pressure and flow velocity monitoring to prevent leakage and maintain safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If charging power is increased to implement ultra-fast charging, then charging efficiency is improved, but heat generation increases and temperature rises affecting safety
Solution Approach 1:
The liquid cooling device is activated before charging begins to establish a coolant flow through the cooling channels. The system performs preliminary cooling to ensure the battery is at an appropriate temperature before ultra-fast charging commences, preventing excessive heat accumulation during high-power charging
Solution Approach 2:
Coolant serves as an intermediary substance that absorbs heat from the battery through thermal conduction in the cooling channels and transports it away from the battery. The coolant acts as a heat transfer medium between the battery and the external cooling system, enabling efficient heat removal during ultra-fast charging
2Temperature
If liquid cooling device delivers coolant to electric vehicle, then heat dissipation is improved, but risk of coolant leakage increases
Solution Approach 1:
Pressure sensors and flow meters continuously monitor the coolant system status and provide feedback to the control unit. When abnormal conditions such as pressure drops or flow interruptions are detected, the system automatically adjusts cooling power or shuts down the coolant pump to prevent leakage, maintaining reliable operation during heat dissipation
Solution Approach 2:
The system establishes emergency shutdown mechanisms and protective barriers before leakage can occur. Pressure relief valves and containment structures are pre-positioned to contain or redirect potential leaks, cushioning against the harmful effects of coolant leakage while maintaining effective heat dissipation during normal operation
3Reliability
If charging device delivers electric energy only after confirming coolant delivery, then charging safety is improved, but charging time increases
Solution Approach 1:
The liquid cooling system is activated and coolant flow is established before the charging process begins. The control unit verifies coolant delivery through sensors that detect flow rate and pressure, confirming the cooling system is ready to handle the heat that will be generated during charging, thereby enabling safe ultra-fast charging without excessive delay
Solution Approach 2:
The coolant delivery verification process is integrated into the charging initiation sequence rather than being a separate sequential step. The cooling system operates continuously throughout the charging process, and the verification of coolant delivery is performed through real-time monitoring parameters that are already being measured for cooling control, minimizing additional time while ensuring safety
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
Enhances charging efficiency and safety by ensuring timely heat dissipation, preventing damage from coolant leakage, and improving user experience through reliable high-power charging.
Implementation Method 1
the coolant may absorb heat generated in the process of charging the electric vehicle, to implement liquid cooling heat dissipation for the electric vehicle
Implementation Method 2
a heat exchanger, a coolant inlet and a coolant outlet of the heat exchanger are connected to a liquid cooling channel of a to-be-cooled component in the charging device
Data Source
Figure 1(a)~1(b)
Figure 2~3
Figure 4
AI summary
This application provides a charging pile (30). The charging pile (30) includes a liquid cooling device (50) and a charging device (40). The liquid cooling device (50) includes a heat exchanger (51). A coolant inlet and a coolant outlet of the heat exchanger (51) are connected to a liquid cooling channel of a to-be-cooled component in the charging device to form a coolant supply loop. The liquid cooling device (50) further includes a liquid cooling connector, and the liquid cooling connector is configured to connect to a liquid cooling port of an electric vehicle (60). The liquid cooling device (50) is configured to output coolant to the electric vehicle (60) through the liquid cooling connector. The charging device (40) is configured to deliver electric energy to the electric vehicle (60) when receiving a packet indicating that the liquid cooling device has delivered the coolant to the electric vehicle (60). In this application, efficiency and safety of charging the electric vehicle can be improved.