直浸式液冷超级快充电缆的螺旋内槽管道设计
Design of Helical-Grooved Pipes for Direct-Immersion Liquid-Cooled Ultra-Fast Charging Cables
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摘要: 直浸式液冷电缆动力线导体与冷却液直接接触,散热效率高,被广泛应用于大功率充电设备的桩-枪双端电气连接中。然而,由于动力线导体浸没于冷却液中,且仅通过两端硬连接部件固定,在使用时充电电缆缆线中动力线导体可能出现偏离液冷管道中心位置的情况,造成液冷管道上的横向热分布不均匀,导致管道局部热老化,从而降低电缆使用寿命。针对该问题,文中提出一种螺旋内槽管道模型,通过几何结构诱导液体横向流动强化换热,并采用COMSOL多物理场分析软件进行仿真计算。结果表明,当液冷管道内壁具有螺旋槽道时,能够通过结构诱导使流体螺旋流动,可提升流体横向换热效率,有效改善了动力线偏心时的横向温度均匀性。该成果为大功率充电桩电缆高效散热管道的改进提供了理论支撑与技术路径。Abstract: Direct-immersion liquid-cooled charging cables, which feature high heat dissipation efficiency, has a wide range application in pile-side electrical connections of high-power mobile charging equipment. However, power line conductors in the cable may deviate from the center of liquid-cooling pipes under external forces, since power line conductors are only fixed by rigid connection components at both ends during use. The deviation will result in uneven heat distribution on cross-section of liquid-cooling pipes, leading to local thermal aging of the pipes and thus reducing service life of the cables. To address the issue, a liquid-cooling pipe model with helical-grooved channels was proposed in the paper, which could utilize its geometric structure to induce transverse liquid flow and enhance heat transfer. In the meantime, COMSOL Multiphysics was employed for simulation calculation. Results showed that liquid-cooling pipes with internal helical-groove channels could effectively improve lateral temperature uniformity when the power line was eccentric by improving fluid motion shape. The achievement could provide theoretical support and technical path for efficient thermal management of high-power charging station cables.
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