CHARGER COOLING
the same experience that you’d have when
fi lling your car with fuel, which is quick, easy
and manageable.”
What followed was Huber+Suhner’s Radox
HPC 400, a cable with a smaller diameter than
before and a cooling system that directs the
coolant to the connecter fi rst – initially around
the pins and then all the way back directly on
the copper wire. “The maximum temperature
the pin can be is 90°C 194°F; the cable surface,
60°C 140°F and the connector itself, 45°C
113°F,” says Göldi. “If it is not being cooled, the
system would completely overheat and burn
the cable within a few minutes.
“There are diff erent ways to cool. We
evaluated all the possibilities and decided to
use non-conductive coolant, which means we
don’t have any insulation issues with the
coolant,” he adds. “The big advantage we have
is that we can cool directly on the copper. We
start the cooling around the pins and on the
way back to the charging station we’re cooling
the copper, so the hottest temperatures of the
copper or the coolant is in the charging system.
Göldi reveals that the next generation of the
cable – Radox HPC 500 – is set for release in
early 2020, off ering better cooling performance
and e ciency. The cables will also be cooler
and more lightweight, which further improves
the operational aspect. “The fi rst development
was focused on safety and functionality, and
now e ciency, fl exibility and serviceability are
the main focuses,” he explains. “One of the
weak points was the design of the interface of
112 // January 2020 // www.electrichybridvehicletechnology.com
the connector – that will now be easier to replace, because
the design itself cannot be changed.”
A price to pay
With the cooling issue under control and the rollout of
fast-chargers continuing, Koblitz sees further improvement
and more manageable costs for the units in the future. “I
don’t think the cooling system itself is a big issue in terms
of cost for a high-power charging station. It’s a contribution
but not the main cost. The cooled cable is not the largest
cost contribution and, while the diff erence in investment
shows in the price the consumer has to pay, they get a
diff erent service and off er,” she reasons. “Instead of
charging at home every night, they can come to one of our
sites, charge for 15-20 minutes and then potentially give
them 400km 248 miles of range.”
3. Huber+Sunher’s Radox
HPC directs coolant to the
connector pins and back
through the copper wire
4. Cables have been
specifi cally designed to
not melt at high
temperatures or see any
insulation shrinkage
3
4
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