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Automotive Engineering ›› 2025, Vol. 47 ›› Issue (9): 1782-1789.doi: 10.19562/j.chinasae.qcgc.2025.09.014

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Single-phase Liquid Cooling Characteristics of High-Power Fast-Charging Cables for Electric Vehicles

Zhilong Zhou,Gangtao Liang()   

  1. School of Energy and Power Engineering,Dalian University of Technology,Key Laboratory of Ocean Energy Utilization and Energy Conservation of Ministry of Education,Dalian 116024
  • Received:2025-03-05 Revised:2025-04-05 Online:2025-09-25 Published:2025-09-19
  • Contact: Gangtao Liang E-mail:gtliang@dlut.edu.cn

Abstract:

With the rapid increase in the number of electric vehicles, the pain points of slow charging and difficult charging of electric vehicles have become more and more obvious. In order to meet the rapid charging demand of electric vehicles, high-power fast charging technology has emerged. However, the elevated charging current will precipitate a precipitous increase in the temperature of charging cable, and its cooling problem has become a significant challenge in the development of high-power fast charging technology for electric vehicles. In this study, the effect of liquid cooling channel arrangement, coolant mass flow rate, and inlet subcooling degree on the temperature distribution of cables are comparatively analyzed by numerical simulation. The results show that when the core cross-sectional area and liquid-cooling channel cross-sectional area remain constant, the cooling effect of liquid-cooling channel external configuration on charging cables is better than that of internal configuration. Increasing the inlet subcooling degree can decrease the temperature of charging cable, however, there exists an optimal mass flux of 500 kg/(m2·s). Under the working conditions specified in this study, the liquid-cooled cable is capable of withstanding a maximum current of 1 250?A, which is ten times of a standard cable.

Key words: charging cable, single-phase liquid cooling, current carrying capacity, channel arrangement