Research on the Performance of Cooling Heat Exchangers for Liquid-Cooled Charging Cables

This study investigated a liquid-cooled charging-cable cooling system for the high-power DC fast charger of electric vehicles. This system utilized perfluoro as the liquid coolant and a serpentine microchannel heat exchanger as the radiator. A mathematical model of the microchannel heat exchanger of this liquid-cooled charging-cable cooling system was established using the ε-NTU and distributed parameter methods. This model was validated through experiments, which demonstrated good consistency between the calculated values and experimental results. By optimizing the flows on both sides of the heat exchanger, along with its structure and configuration, the heat exchange performance was effectively improved while reducing the power consumption. The system employed a parallel arrangement of 28 rows of tubes, which resulted in a temperature reduction of 1.81-2.49 ℃ for the coolant at the gun head and a maximum temperature decrease of 3.51-6.44 ℃ for the charging cable. The results of this study provide valuable insight into the design of the heat exchangers used in liquid-cooled charging-cable cooling systems.