volume | PIER Journals

2025-01-18

Structural Optimization and Performance Evaluation of Liquid Cooled Super Fast Charging Cable Based on Multi-Physics Coupling Calculation

Yanrong Ni,

Dr. Yanrong Ni

Henan Institute of Technology

China

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Shupeng Zhao,

Dr. Shupeng Zhao

Wuxi Xinhongye Wire&Cable Co., Ltd.

China

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Xiaohe Zhao,

Dr. Xiaohe Zhao

Henan Institute of Technology

China

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Kaituo Zhang

Dr. Kaituo Zhang

Henan Institute of Technology

China

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Progress In Electromagnetics Research C, Vol. 152, 67-72, 2025

doi:10.2528/PIERC24112003

Abstract

Super fast charging is a key solution to addressing the issue of electric vehicles. In response to the demand for increased current-carrying capacity and lightweight cables in super-fast charging system, optimization design and verification were conducted in this study employing a multi-physics field analysis method. A single-core cable was selected as the research subject, and both the Ohmic loss and temperature distribution were analyzed under the excitation of electric vehicle cold charging current. The influence of different cable core shapes, coolant flow rates, cooling channel structural parameters, and other factors on the maximum temperature rise of the charging cable were compared and analyzed. The calculation results indicated that, under the identical cable core cross-sectional and operating conditions, rectangular cross-section cables exhibited superior heat dissipation performance compared to circular cross-section cables. It was found that the flatter the cable core is, the better the heat dissipation performance is. Under specific operating conditions, the cross-sectional area of the flat linear shape could be reduced appropriately, as increasing the size of the liquid cooling channel would help reduce the overall mass of the cable. These findings provide valuable insights for enhancing the heat dissipation performance and lightweight design of liquid-cooled charging cables in supercharging applications.

Citation

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Yanrong Ni, Shupeng Zhao, Xiaohe Zhao, and Kaituo Zhang, "Structural Optimization and Performance Evaluation of Liquid Cooled Super Fast Charging Cable Based on Multi-Physics Coupling Calculation," Progress In Electromagnetics Research C, Vol. 152, 67-72, 2025.
doi:10.2528/PIERC24112003

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