Thermal optimization design of high-power charging station charging module

Abstract

Abstract When facing significant heat generation from a 30 kW high-power charging station, traditional air-cooling forced convection methods are insufficient to meet the cooling requirements. In this study, based on an in-depth analysis of power modules, we designed a key component of the liquid cooling system, the cold plate, through theoretical calculations. Using simulation techniques, we analyzed the temperature distribution within the cold plate and performed design optimization under conditions of a 4C charging rate and a thermal load of 1598 W. Considering the actual operating environment of the charging equipment, we selected a 50% volume fraction of ethylene glycol-water solution as the coolant and simulated its performance under extreme outdoor conditions of 50°C. Simulation results showed that the optimized liquid-cooled cold plate module achieved a junction temperature of 69.73°C, significantly lower compared to the initial temperature of 109.9°C, resulting in an approximately 36% improvement in heat dissipation efficiency. This significant enhancement not only highlights the advantages of the liquid cooling system in managing the thermal load of high-power charging stations but also addresses the issue of excessive heat load faced by traditional cooling methods. The outcomes of this research provide important theoretical and practical foundations for the thermal design of charging equipment, which is expected to play a critical role in improving the performance and reliability of charging stations.