Liquid cooling charging module is the new technical route for EV charging

For charging station operators, there are two most troublesome issues: the failure rate of charging piles and complaints about noise nuisance.

The failure rate of charging piles directly affects the profitability of the site. For a 120kW charging pile, a loss of nearly $60 in service fees will be caused if it is down for one day due to a failure. If the site fails frequently, it will affect the charging experience of customers, which will bring immeasurable brand loss to the operator.

The main causes for the failure of the charging pile comes from the failure of the charging module. At present, the charging piles popular in the industry use air-cooled heat dissipation modules. They use a high-speed fan to exhaust the air powerfully. The air is sucked in from the front panel and discharged from the rear of the module, thereby taking away the heat from the radiator and heating components. However, the air will be mixed with dust, salt mist and moisture, and will be adsorbed on the surface of the internal components of the module, while flammable and explosive gases will be in contact with conductive components. Internal dust accumulation will lead to poor system insulation, poor heat dissipation, low charging efficiency, and shorten the equipment lifespan. In the rainy season or humidity, the accumulated dust will become moldy after absorbing water, corrode components, and short circuit will lead to module failure.

To lower the failure rate and fix the noise problems of existing charging systems, the best way is to use liquid-cooling charging modules and systems. In response to the pain points of charging operation, UUGreenPower has launched the liquid cooling charging module and the liquid cooling charging solution.

The core of the liquid-cooling charging system is the liquid-cooling charging module. The liquid-cooling charging system uses a water pump to drive the coolant to circulate between the inside of the liquid-cooling charging module and the external radiator to take away the heat from the module. The heat dissipates. The charging module and the heat-generating devices inside the system exchange heat with the radiator through the coolant, completely isolated from the external environment, and there is no contact with dust, moisture, salt spray, and flammable and explosive gases. Therefore, the reliability of the liquid-cooling charging system is much higher than that of the traditional air-cooling charging system. At the same time, the liquid-cooling charging module does not have a cooling fan, and the cooling liquid is driven by a water pump to dissipate heat. The module itself has zero noise, and the system uses a large-volume low-frequency fan with low noise. It can be seen that the liquid-cooling charging system can perfectly solve the problems of low reliability and high noise of the traditional charging system.

The liquid-cooling charging modules UR100040-LQ and UR100060-LQ exhibited adopt a hydropower split design, which is convenient for system design and maintenance. The water inlet and outlet terminals adopt quick-plug connectors, which can be directly plugged and pulled without leakage when the module is replaced.

UUGreenPower liquid cooling module has the following advantages:

High protection level: Traditional air-cooling charging piles generally have an IP54 design, and the failure rate remains high in application scenarios such as dusty construction sites, high-temperature, high-humidity, and high-salt fog seasides, etc. The liquid-cooling charging system can easily achieve an IP65 design to meet various applications in harsh scenarios.

Low noise: The liquid-cooling charging module can achieve zero noise, and the liquid-cooling charging system can adopt a variety of thermal management technologies, such as refrigerant heat exchange and water-cooling air-conditioning to dissipate heat, with good heat dissipation and low noise.

Great heat dissipation: The heat dissipation effect of the liquid-cooling module is much better than that of the traditional air-cooling module, and the internal key components are about 10°C lower than the air-cooling module. Low temperature energy conversion leads to higher efficiency, and the lifespan of electronic components is longer. At the same time, efficient heat dissipation can increase the power density of the module and be applied to a higher power charging module.

Easy maintenance: The traditional air-cooling charging system needs to regularly clean or replace the filter of the pile body, regularly remove dust from the pile body fan, remove dust from the module fan, replace the module fan or clean the dust inside the module. Depending on different application scenarios, maintenance is required 6 to 12 times a year, and the labor cost is high. The liquid-cooling charging system only needs to regularly check the coolant and clean the radiator dust, which greatly simplifies the operation and maintenance work.

Low TCO: The current liquid-cooling charging system is rarely used, so the equipment cost is higher than that of the traditional air-cooling system. But from the perspective of equipment life cycle, the whole life cycle cost of liquid cooling system is lower than that of the air cooling system.

Normally, the service life of the conventional air cooling system is 3 to 5 years, and the service life of the liquid cooling system exceeds 10 years.

Conventional air-cooling systems require professional maintenance about 6 times a year, while liquid-cooling systems only require routine inspections. The failure rate of conventional piles is much higher than that of liquid-cooling piles. Once it fails, it will affect the charging efficiency and profitability of the site.

Generally speaking, the charging efficiency of the liquid-cooling module is 1% higher than that of the air-cooling module, and the 30% utilization rate of the 480kW system can save about $1625 in electricity bills per year. High-power charging increases the site arrival, and increase the equipment utilization rate.

So when considering the life of the equipment, the equipment cost of the liquid-cooling charging system is lower than that of the traditional air-cooling system; at the same time, the annual operation and maintenance cost of the liquid-cooled system is much lower than that of the air-cooling system, and considering the operating efficiency of the charging station , the rate of return of the liquid-cooling charging system is much higher than that of the traditional air-cooling system.

The high protection level of the liquid-cooling charging system makes the system widely used in high-dust mining sites, high-temperature, high-humidity, high-salt fog, and typhoon-prone seaside; Scenarios with explosion-proof requirements such as gas stations and underground mines. The advantage of low noise is also conducive to the use of liquid cooling systems in noise-sensitive scenes such as residential areas and office areas.