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  • Workersbee 700A Liquid-Cooled EV Chargers: Fast, Safe, and Sustainable Workersbee 700A Liquid-Cooled EV Chargers: Fast, Safe, and Sustainable
    Oct 15, 2024
    In the previous article, we discussed the importance of liquid cooling technology for DC Fast Charging, which enables electric vehicles to achieve excellent charging experiences. This includes enhancing the charging power limit of High-power charger (HPC), achieving more efficient, energy-saving, and reliable charging.   This article will delve further into the key components of liquid cooling charging, providing insights to help you choose suitable products for the Plug-in EV Charging business.   The main components of the liquid-cooled charging plug include the Coupling Part, Enclosure, Liquid-cooling Assembly Part, Terminal Pin, Sealing Part, and Cable Clip.   Among them, the Liquid Cooling Assembly is the key component of the liquid-cooled charging plug. Due to the existence of contact resistance and connection resistance, the charging plug pin terminal heats up more than other parts like the cable conductor during Rapid Charging, necessitating additional forced cooling. This is where the liquid cooling assembly comes in, establishing a cooling connection through its structure and utilizing the coolant circulation to achieve heat dissipation. The design principle of the liquid cooling assembly is to have a simple structure, easy production, and most importantly, to ensure good temperature rise performance. The basic structure includes joints, screws, fixing nuts, thermal conductive materials, and seals. The double-sided joints are responsible for the inflow and outflow of coolant, creating a sealing environment by over-connecting with the liquid cooling tube and meeting the sealing requirements of the coolant. Generally, a simple and easy-to-operate pagoda joint structure is adopted, with a smooth surface to avoid sharp structures causing damage to the liquid cooling tube. For water cooling solutions, the coolant does not directly contact the metal conductor. The thermal conductive material is located between the terminal pin and the coolant to conduct heat, needing to balance thermal conductivity and insulation. Compared to ordinary DC cables, Liquid-cooled Cables not only have conductors but also integrate a coolant channel, i.e., the liquid cooling tube. The liquid cooling tube carries the coolant, the conductor wraps around the liquid cooling tube, and the outer layer is insulated. The structure of the liquid-cooled cable determines the internal structure design of the charging plug.   Public Charging Infrastructure has the following standards when choosing liquid-cooled cables: 1. Good flexibility, avoiding stiffness for convenient handling. 2. Good appearance, avoiding excessively thin outer jacket due to the pursuit of a small cable diameter. 3. Low temperature rise of the outer sheath to ensure a good charging experience and safety. 4. Excellent cable and pin welding quality to ensure the reliability of the Liquid cooling HPC.   The Liquid Cooling tube, as the key component of the liquid-cooled cable, plays a crucial role in transferring the coolant and heat. The inner diameter of the liquid cooling tube affects the overall flow resistance. The smaller the inner diameter, the greater the flow resistance, and the lower the efficiency of liquid cooling.   Electric Vehicle Supply Equipment (EVSE) liquid-cooled cables require limiting charging when beyond a certain length - one reason is that longer cables generate more heat, and another reason is that the longer cables have greater flow resistance. However, it also has to consider the lightweight of the cable. The outer diameter of the liquid cooling tube cannot be too large, which requires a balanced solution. In addition, The liquid cooling tube also needs to have a certain strength, sufficient deformation, and toughness.   In EV Ultra-Fast Charging, another important component is the Liquid Cooling System, which consists of a pump, radiator, oil tank, and connecting pipes. The heated coolant is cooled through the heat exchanger and then returned to the oil tank, and the cooled coolant is pumped back to the liquid cooled charging plug through the coolant pump. Liquid cooling systems can be categorized into automatic control and non-automatic control systems based on whether a charger is needed to control the operation of the pump and heat exchanger. Typically, liquid cooling systems include temperature sensors, liquid level sensors, pressure sensors, and other functional components. For automatic control systems, the charger only needs to provide power and start signals. Advantages of Workersbee’s liquid-cooled charging cable to business Workersbee’s CCS2 liquid-cooled charging cable can provide up to 700A of current. The product has passed CE certification and uses user-friendly TPU cable. Its excellent charging performance and high reliability have been highly recognized by our customers. The advantages are mainly reflected in the following aspects: 1. Reliable performance: Carefully designed the structure and material scheme of the liquid cooling tube and liquid cooling cable, using liquid cooling tubes with better chemical resistance, and excellent overall performance. 2. Enhanced user experience: The cable is more flexible and easier to handle. 3. Reliable safety: Effectively control the temperature rise of the outer sheath to avoid safety risks caused by overheating. 4. Solid production craftsmanship: Excellent pin welding quality, strict control of production 5. Cost savings: Applying terminal quick-change technology eliminates the need to replace the entire piece, reducing maintenance costs. 6. Customization options: Workersbee offers customizable liquid-cooled charging cables to meet your specific needs, including logos, different lengths, connector types, and current ratings. 7. Industry compliance: Workersbee's cables comply with industry standards and certifications, ensuring compatibility and interoperability with a wide range of EVs and charging infrastructure.   Conclusion As a key component of the liquid-cooled charging plug, the liquid-cooling assembly has connectors on both sides responsible for coolant inflow and outflow, connecting to the liquid-cooled tubes carrying the coolant. Heat is transferred via the flow of coolant to the liquid cooling system heat exchanger for dissipation and then circulated back to the liquid-cooled charging plug, maintaining the charging system, including the plug and liquid-cooled cable, at an appropriate temperature to ensure stable transmission of high currents. Only by comprehensively balancing the roles advantages and disadvantages of each component and designing a more reliable liquid cooling technology solution can the performance of liquid cooling be better utilized.   As a pioneer in the EV charging industry, Workersbee has accumulated rich experience in the research, development, production, sales, and service of liquid-cooled charging cables. Our products and technologies have been certified by authoritative testing and have been highly recognized in the market. We look forward to contributing to the development of global sustainable green energy transportation. Contact us to order the latest liquid-cooled charging plugs for CHARGING AHEAD!  
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  • Power Up: A Guide to Charging Speed of Different Types of Chargers Power Up: A Guide to Charging Speed of Different Types of Chargers
    Mar 21, 2024
    The rapid development of electric vehicles is inseparable from the support of EVSE chargers. Charging an Electric car takes more than refilling a gas car from empty to full. Meanwhile, different types of chargers provide different charging speeds. The difference ranges from more than 20 minutes to dozens of hours. If more car owners encounter the latter, the popularity of electric vehicles will stall.     We need to understand the charging speeds of different types of chargers to ride the wave of electrified transportation.   What factors may affect charging speed 1. Charger types: They can be roughly divided into AC chargers, which charge relatively slowly, and DC chargers, which charge faster. AC is further divided into Level 1 and Level 2, which will be explained below. 2. Charger output power: A charger with greater output power will deliver more power to the car per unit time and charge faster. 3. EV battery capacity: It determines how much energy can be stored. Larger batteries will take longer to recharge. 4. State of Charge: The current SOC of the battery is closely related to the Charging Speed. In the range of 20%~80%, you will get better charging efficiency. 5. Vehicle charging capacity: The efficiency of the onboard charger (AC charging) and Battery Management Systems (DC charging) will also affect the charging speed, and the performance of each car is different. The car and the charger will have current and voltage limitations that need to be matched to transfer energy. 6. Temperature: Whether too cold or too hot can affect charging speed and battery performance. Cold may inhibit or prevent charging, while high temperatures may slow charging due to thermal management. In addition to the above, factors such as battery aging, other electrical loads during charging, etc. can also affect the charging speed.   Types of Chargers   Level 1 Charger (AC) The slowest but most convenient AC charger that plugs directly into a standard 120V household outlet for charging. The output power ranges from 1 to 1.92kW, charging approximately increases by 3-5 miles per hour, and it takes roughly dozens of hours to refill a BEV. It's frustrating, and perhaps why many consumers don't initially consider EVs. But it is suitable for car owners who have low commuting needs and can charge at home overnight.   Level 2 Charger (AC) Provides up to 19.2kW power via 240V, greatly improves charging speed compared to Level 1 chargers. It is the favorite type of charger for EV owners when balancing many aspects (charging speed, charging cost, battery health, etc.). It is often used for charging at homes, or in public places such as workplaces, shopping districts, or roadsides. Because drivers usually park in these places for a long time. Typically, Level 2 chargers can add 10-50 miles of range per hour, making it easy to fully charge an electric vehicle in a few hours or overnight. Aside from fixed wall box Level 2 chargers or EV Charging Stations offering Level 2 charging in residential areas or public spaces, many drivers are now opting for Portable Electric Vehicle Chargers. Not only can they provide Level 2 charging speeds, but they are also mobile and portable, making them convenient for drivers to recharge on trips. The portable chargers of Workersbee, a long-established EVSE manufacturer, provide a variety of product models to choose from. They are lightweight, stylish, easy to operate, and have reliable charging and protection performance. The powerful control box provides diversified Smart Charging Solutions.     DC Fast Charging The DC fast charger converts the AC power from the grid into DC power and directly delivers it to the battery for storage, making charging more efficient. It usually provides 25-400kW of power, which makes it possible to charge the battery to 80% in as quickly as 20 minutes. Different power levels also mean huge differences in charging time.   Because of high electrical requirements and high construction and maintenance costs, DC fast chargers are usually established along highway corridors and at public charging stations. It is more suitable for road trips and drivers who want to gain energy quickly.   The most popular High-Power Chargers today are none other than Tesla. Its Supercharger can add 200 miles of range to an electric vehicle in just 15 minutes. Powered by high reliability, high efficiency, and a comfortable charging experience, it dominates the North American charging market.  Since Tesla opened the NACS charging standard at the end of 2022, EVSE manufacturers have actively poured into the NACS connector market.   Workersbee's R&D team quickly established a product project team last year to develop AC and DC plug products based on the NACS charging standard, which will be launched soon. We are deeply committed to Fast Charging Technology, further enriching our product models and expanding sales areas. With innovative, high-quality, and diversified R&D and production systems, we have built an outstanding DC fast-charging product matrix.     Wireless Charging Wireless Charging uses electromagnetic induction to transmit electrical energy to the vehicle's battery without the cable connections. Charging speed depends on the Wireless EV Charging Pads's power and distance from the vehicle. Charging can be done while parked on the road or while driving, but the charging speed is not very high, the infrastructure requirements are very high and the investment is large. Although it sounds very free and wonderful, there is still a long way to go before the goal of better serving electric vehicles.   Conclusion AC Level 1 chargers can be powered by a regular household outlet and charge at 3-5 miles per hour. Suitable for charging at home or for low commuting requirements. Although it is the slowest charging solution, it does not require the additional cost of a charger installation. AC Level 2 is more suitable for charging in long stops, typically at homes and workplaces. A full night or daytime work hours can make the car almost fully charged. Installation costs and charging fees are low, and sometimes can take advantage of time-of-use rates. If there are higher charging needs and shorter charging time constraints, DCFC is a charging solution that will surprise drivers. They are often found on highways and urban public charging stations and are the fastest charging solution. The cost of building a site and charging is high, but it may only take 20 minutes to complete the charging task.   Market Insights Although the charging speeds of AC and DC are vastly different. But for the health of vehicle batteries, we know that AC slow charging is better. Not to mention that charging speed also depends on the vehicle itself. Most PHEVs do not work with fast chargers. Different charging methods have advantages and disadvantages and are suitable for different charging scenarios. Increasing charging speed significantly impacts car owners’ experience, which has far-reaching implications for the popularity of electric vehicles.   From the perspective of the charging market, we do not define a certain charger as always being the best choice. We can only say that it is more suitable for certain demand scenarios.   As a major player in the Electric Vehicle Charging market, charger and charging plug/cable manufacturers will also encounter some technical challenges during the research and development process when improving the charging speed of their products: l In DCFC, limitations and risks caused by the temperature rise of connectors, plugs, and cables; l High-frequency use of high-current fast charging may cause damage to battery health; l The surge in electric vehicle charging demand brings excessive grid load, etc. Workersbee has always paid attention to technological development and has made breakthrough innovations in multiple temperature control mechanisms, liquid cooling systems, and natural cooling technology. Solutions using new technologies have also gained attention and praise in the market. We are also working hard to find a better balance of charging speed and technology, as this is critical to both the owner's experience and the adoption of electric vehicles.   If your business requires solutions suitable for multiple charging scenarios, please discuss them with us to discover more possibilities. We welcome your curiosity and look forward to sharing and exploring more diversified technological possibilities.
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