Application of Electric Water Pumps in Liquid-Cooled Liquid Cooling Supercharger

With the rapid development of electric vehicles (EVs), ultra-fast charging technology has become a key focus to reduce charging times and improve user convenience. However, high-power charging generates significant heat, which can degrade charging efficiency and even damage components. To address this challenge, liquid-cooled ultra-fast charging guns have been introduced, utilizing advanced thermal management systems where electric water pumps play a critical role.

Role of Electric Water Pumps in Liquid-Cooled Charging Systems

Electric water pumps are essential for circulating coolant in liquid-cooled charging systems. Their primary functions include:

1. Efficient Heat Dissipation

• During ultra-fast charging (e.g., 350 kW or higher), the charging cable and connector generate substantial heat due to high current flow (up to 500A or more).

• The electric pump drives coolant (typically a water-glycol mixture or dielectric fluid) through cooling channels around the cable and connector, absorbing and transferring heat away from critical components.

2. Precision Flow Control

• Smart pumps with variable speed control adjust coolant flow based on real-time temperature sensors, ensuring optimal cooling without unnecessary energy consumption.

3. Compact and Lightweight Design

• Unlike traditional mechanical pumps, brushless DC (BLDC) electric water pumps are compact, lightweight, and energy-efficient, making them ideal for portable charging guns.

4. Noise Reduction & Reliability

• Advanced electric pumps operate quietly, improving user experience, while their sealed designs prevent coolant leakage, enhancing durability.

Real-World Examples

Several leading EV manufacturers and charging infrastructure providers have adopted liquid-cooled charging solutions with electric water pumps:

1. Tesla V4 Supercharger (Liquid-Cooled Cable)

• Tesla’s latest V4 Supercharger uses a liquid-cooled cable design with an integrated electric pump to maintain safe temperatures during 250 kW+ charging.

• The pump ensures consistent coolant flow, allowing thinner, more flexible cables while handling extreme power loads.

2. Porsche 800V High-Power Charging (HPC) System

• Porsche’s 270 kW/350 kW chargers for the Taycan employ liquid cooling with an electric pump to sustain 800V ultra-fast charging without overheating.

• The system dynamically adjusts pump speed based on thermal load, maximizing efficiency.

3. ABB Terra 360 (360 kW Charger)

• ABB’s Terra 360, one of the fastest commercial chargers, integrates a liquid-cooled gun with an electric pump to support 360 kW output.

• The pump enables continuous high-power charging by maintaining stable connector temperatures.

Technical Advantages Over Air Cooling

• Higher Power Tolerance: Liquid cooling allows for higher sustained currents (e.g., 500A+) compared to air-cooled systems (limited to ~200A).

• Longer Lifespan: Reduced thermal stress on cables and electronics extends component life.

• User Safety: Prevents overheating risks, ensuring safe touch temperatures even during peak loads.

Future Trends

As charging power escalates (towards 500 kW+), liquid cooling with smart electric pumps will become standard. Innovations like magnetic-drive pumps (leak-free) and AI-driven thermal management will further optimize performance.

In summary, electric water pumps are indispensable in liquid-cooled ultra-fast charging guns, enabling faster, safer, and more reliable EV charging infrastructure. Their integration exemplifies how advanced thermal management solutions are driving the next generation of e-mobility.