Background

High Power Charging (HPC) continues to grow in market demand due to its advantages of significantly reduced vehicle charging time and shorter queuing durations.

However, with high-power charging, the energy transferred per unit time increases substantially, leading to considerable temperature rises in cables and connectors. To ensure charging safety, an effective cooling system is essential.

The liquid-cooling module in the charging station addresses this challenge by incorporating a dedicated liquid circulation channel between the cable and the charging gun. This channel is filled with a coolant media that absorbs heat generated during charging. A pump drives the coolant to circulate, effectively transferring heat away from critical components.

The liquid-cooling module uses the internal circulation of coolant within cooling plates to exchange heat with the external environment, enhancing overall thermal management.

 Ultrasonic Flow Meters Application in Liquid-Cooled Charging Station

Temperature sensors are installed at both the inlet and outlet of the liquid-cooling terminal. A flow meter is placed in the inlet tubing. Signals from the temperature sensors and flow meter are fed into the controller, which dynamically adjusts the electric proportional valve and compressor output accordingly.

The controller uses the inlet temperature data to precisely regulate the compressor’s output power, stabilizing the coolant temperature at the terminal inlet near a constant setpoint. This ensures the rated temperature of the input coolant is maintained.

The controller also uses real-time flow measurements from the flow meter to maintain a steady flow rate in the inlet pipeline.

Based on real-time flow rate, the control system dynamically adjusts the flow in short-circuit branches to regulate the main loop’s flow rate, guaranteeing the rated input flow without requiring additional variable-frequency water or oil pumps. This approach reduces costs, simplifies the system’s structure, and improves reliability.

Advantages

1. Real-time Flow Control

The flow meter continuously monitors coolant parameters and feeds data to the controller, enabling dynamic adjustment of the main loop flow to ensure stable coolant delivery at the liquid-cooling terminal—without the need for variable-frequency pumps.

2. Measureable Various Coolants

· Water and propylene glycol mixtures

· Insulating oils

· Other specialized coolants

3. Multiple Output Modes

Versatile flow metering to suit diverse operational requirements. Support OEM.

4. Low Cost, Simple Structure, High Reliability

The robust ultrasonic flow sensor reduces long-term maintenance costs, enhancing operational stability.

This liquid-cooled approach ensures efficient thermal management for high-power charging stations, enhancing safety, reliability, and overall performance while optimizing cost and system complexity.

XY-TEK ultrasonic flow sensor helps deliver higher liquid cooling efficiency.

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