Automotive Ultra High Speed Charging Connector Cooling

China's electric vehicle market will begin competition for ultra-fast charging. The largest thermal production working mode of electric vehicles is DC charging. The entire charging high-voltage circuit in the charging scenario will generate a lot of heat. The greater the power, the greater the heat loss. According to the conservation of energy, heat needs to find a way to discharge. High-power fast charging, on the charging facility side, enter the battery charging interface from the charging seat, and enter the battery core and surface from the high-voltage contactor. At present, in high-voltage connectors, charging connectors, and 400V systems, the charging current is controlled within 250A, no charging cooling system is required, and the charging power is about 70 ~ 90 kilowatts. Therefore, the charging interfaces are all water-cooled, which has become the standard configuration of the new generation of charging files.

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Using charging water cooling technology, compared with traditional DC charging gun and cable, water-cooled charging gun and charging cable add cooling pipes on the charging gun, cable, charging file circuit, add pipes for cooling water inside the cable, compatible with different requirements of 400V and 800V, ensure that the charging interface temperature rise will not exceed. Using coolant to cool the termination simplifies operation by reducing cable cross-sectional area requirements and reducing the weight of the actual plug and cable. Water-cooled charging will only reduce the charging temperature. From the charging pile to the charging gun, about 50% of this charging circuit depends on this system, and the other half goes from the charging socket installed on the car to the battery charging port, which has to withstand large currents. Therefore, a DERATING curve can be introduced, which is the relationship of the maximum safe continuous current that the connector can accept at a range of external ambient temperatures for a connector matched to a particular wire. It is promised here that at high ambient temperatures, the highest safe continuous current of the connector will gradually decrease, the hottest point of the connector is the terminal pair position, and the heat source includes the working environment input and connector current. Under the premise that the circuit resistance, power-on time and application environment are constant, the greater the current, the more heat is generated. Therefore, with the increase of the ambient temperature of the connector application, under the cut-off temperature limit, the possible temperature rise margin of the connector oil will be reduced, the circuit resistance and electrical time will remain unchanged, and only the current will be limited, thus reducing the temperature rise. Among them, the electrical equivalent circuit consists of thermal resistance and heat capacity, and the method of controlling the temperature rise is to eliminate the heat by adding cooling pipes. Inside the socket, by changing the connection mode and reliability, including changing the connection terminal coating, changing the wire and terminal extrusion mode (ultrasonic welding), increasing the extrusion area, and the like, the contact resistance can be reduced, thereby reducing the generation of self-heat. At present, the thermal management of fast charging may change quite a lot in the subsequent technology. --We not only have to use a high voltage of 800V, but also continue to increase the current from 250A to 500A before we can consider entering the 400kW stage.

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