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Keywords

EV charging cable, high‑power charging, two‑phase cooling, heat transfer characteristics

Abstract

Direct current‑based high‑power charging (DC‑HPC) technology can significantly reduce the charging time of electric vehicles and therefore alleviates concerns about charging duration. However, the rapid temperature increase of charging connectors under high voltage and current poses a challenge, impacting their lifespan and safety. This paper proposes a phase change cooling technology for the high‑power super‑charging connectors. Through a comparative numerical analysis of the single‑phase and phase change cooling performance, the influence of coolant type, flow rate and casing thickness on the thermal behavior of the charging cable with active cooling are investigated. The results indicate that the cable temperature can be reduced to 69 ℃ when using 40 ℃ water as single‑phase coolant at a 5 min charging time and a 600 A loading current. In contrast, the two‑phase cooling coolant can further decrease the cable temperature to below 40 ℃. The charging cable temperature exhibits a decrease with increasing two‑phase coolant flow and an increase with rising coolant sleeve thickness. The coolant sleeve thickness has a more significant effect on cable temperature than the coolant flow rate.

DOI

10.19781/j.issn.1673-9140.2024.01.020

First Page

201

Last Page

207

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