Charging station liquid cooling Control Logic

The liquid cooling system of the charging station primarily consists of a circulating water pump, a liquid cooling plate, a radiator, an electronic fan, an electronic oil pump, and a plate heat exchanger.
The integrated liquid cooling system significantly enhances the functionality of the charging station by simplifying the design of the charging module’s air duct and reducing the overall volume of the station. Additionally, it contributes to a higher protection level for the charging pile, safeguarding it against water, dust, insects, and other environmental factors that could affect its longevity. This improvement not only decreases the maintenance frequency but also enhances the overall user experience.
The high convection heat transfer coefficient and uniform temperature distribution of the liquid cooling system simplify the design of the loop.
The side-in and side-out method is employed to ensure that each component in the loop has an equivalent flow length and convergent flow resistance, thereby promoting uniform flow distribution.
The product features a quick plug-in structure, making it modular and easy to install.
The design can be easily adapted to accommodate the requirements of various power piles.
Charging station liquid cooling System Principle
The system employs variable frequency fans and water pumps to accommodate the heat exchange requirements of the charging module under various charging conditions, thereby enhancing the energy efficiency of the system.

- At low load:
Reduce fan speed and consumption to minimize noise and energy usage.
- At high load:
Increase the fan speed, adjust the water pump speed, optimize energy efficiency, and enhance noise, vibration, and harshness (NVH) as well as durability.
- When the system experiences a leak:
When the coolant level falls below the minimum threshold, the system sends a safety warning to the main computer to prevent charging failures.
- When the water temperature is excessively high:
When the water temperature exceeds the safe threshold, an alarm will be triggered to notify the central control system to reduce the charging power, thereby ensuring the safety and reliability of the system.
- When the ambient temperature is excessively high:
If the ambient temperature is excessively high, instruct the system to decrease the charging output power.
Charging station liquid cooling Device Features
Sequence | Device | Function | Type | Protection grade | RHOS |
1 | Radiator | Air-cooled convective heat exchanger | Tube type | NA | 2 |
2 | Water pump | Charging station water cycle | AC220/DC24V | IP67 | 2 |
3 | Cold plate | IGBT heat exchanger | Welding type | NA | 2 |
4 | Fan | Forced ventilation device | AC220/DC24V | IP54 | 2 |
5 | Board replacement | Oil-water heat exchanger | Aluminum sheet metal | IP67 | 2 |
6 | controller | system controller | PCBA | IP54 | 2 |
7 | Water temperature sensor | Temperature detection | 5V DC | IP67 | 2 |
8 | Environmental temperature sensor | Temperature detection | 5V DC | IP67 | 2 |
9 | Oil pump | Charging gun fluorinated oil circulation device | DC 24V | IP67 | 2 |
10 | oil temperature sensor | Temperature detection | 5V DC | IP67 |

Charging station liquid cooling Water Circulation Pump
Compared to air-cooling systems, liquid-cooling structures significantly reduce the space required, thereby enhancing the heat transfer coefficient of the system. This compact design addresses the spatial inefficiencies associated with air duct layouts and conserves resources during the installation of charging stations.

Charging station liquid cooling Device Features
Sequence | Device | Function | Type | Protection grade | RHOS |
1 | Radiator | Air-cooled convective heat exchanger | Tube type | NA | 2 |
2 | Water pump | Charging station water cycle | AC220/DC24V | IP67 | 2 |
3 | Cold plate | IGBT heat exchanger | Welding type | NA | 2 |
4 | Fan | Forced ventilation device | AC220/DC24V | IP54 | 2 |
5 | Board replacement | Oil-water heat exchanger | Aluminum sheet metal | IP67 | 2 |
6 | controller | system controller | PCBA | IP54 | 2 |
7 | Water temperature sensor | Temperature detection | 5V DC | IP67 | 2 |
8 | Environmental temperature sensor | Temperature detection | 5V DC | IP67 | 2 |
9 | Oil pump | Charging gun fluorinated oil circulation device | DC 24V | IP67 | 2 |
10 | oil temperature sensor | Temperature detection | 5V DC | IP67 | 2 |

Charging station liquid cooling Modular takeover method

Simulation model based on the platform:
- Reserve the coolant inlet and outlet to effectively address the challenges of waterproofing and dustproofing the system.
- The charging module is compact and lightweight.
- No air duct is required, and the modular design is more straightforward.
- Adopt a quick plug installation structure to enhance efficiency and reduce process costs.
- PA12 integrated cooling pipe is designed for use in cooling systems of new energy vehicles, offering high reliability.
- Quick plug sealing guarantees consistent assembly quality.
Charging station liquid cooling Computational simulation
Angpai Liquid Cooling Module
Based on the platform simulation model, we can quickly analyze the actual performance of the system selection. This approach effectively enhances development speed and allows for the early prediction of risks. Additionally, products within the same series can be simulated and calculated on the same platform, ensuring complete parametric design and increased reliability.

The simulation system includes:
- Cabinet System Heat Exchange
- Charging Gun Heat Exchange Performance
- Oil Circuit Resistance
- Water Circuit Flow Resistance Characteristics
Charging Station Liquid Cooling: A Game-Changer for EV Infrastructure
With the rapid adoption of electric vehicles (EVs) worldwide, charging station technology is evolving to meet increasing demand. One of the critical innovations revolutionizing this space is liquid cooling systems. As EV charging stations become more powerful, delivering ultra-fast charging speeds, managing heat effectively is essential to ensure safety, efficiency, and durability. Liquid cooling technology has emerged as a robust solution to these challenges, enabling the next generation of high-performance charging stations.
The Role of Liquid Cooling in EV Charging Stations
Liquid cooling is a thermal management system that uses a liquid medium to transfer heat away from critical components. In EV charging stations, where high power outputs generate significant heat, this technology is essential. Traditional air cooling methods often fall short in maintaining optimal operating temperatures for high-power systems, especially those exceeding 150 kW.
Key Benefits of Liquid Cooling:
Enhanced Efficiency: Liquid cooling systems are highly effective at dissipating heat compared to air cooling. They allow charging stations to operate continuously at peak performance without overheating.
Compact Design: Liquid cooling enables smaller and more compact designs by reducing the need for large heat sinks or fans, making it easier to install stations in urban areas with limited space.
Increased Safety: Overheating poses risks to both hardware and users. Liquid cooling ensures stable temperatures, minimizing the chances of equipment failure or accidents.
Support for Ultra-Fast Charging: With the growing demand for charging stations that deliver power outputs of 350 kW or more, liquid cooling becomes indispensable for handling the heat generated during ultra-fast charging sessions.
How Liquid Cooling Works
The process of liquid cooling involves circulating a coolant—a specially formulated liquid with high thermal conductivity—through a network of pipes and heat exchangers within the charging station. Key components of a liquid cooling system include:
Coolant Pump: Circulates the liquid through the system.
Heat Exchanger: Transfers heat from the components to the coolant.
Radiator: Dissipates heat from the coolant into the surrounding environment.
Temperature Sensors: Monitor and regulate the system to ensure optimal performance.
The coolant absorbs heat from high-temperature components, such as charging cables and power converters, and transfers it to the radiator, where it is released into the air. This closed-loop system ensures efficient heat management even during high-demand usage.
Applications in High-Power Charging Stations
Liquid cooling systems are particularly vital for high-power charging stations designed for ultra-fast charging. Such stations are equipped with high-capacity power modules and advanced charging cables capable of delivering large amounts of energy in a short time. However, this level of performance generates significant heat, which can degrade components or reduce efficiency if not properly managed.
For example, ultra-fast charging cables often require active cooling to maintain safe operating temperatures. Liquid-cooled cables, which integrate cooling channels within the cable structure, ensure that heat is effectively dissipated, enabling users to charge their vehicles safely and quickly without overheating the equipment.
Challenges and Innovations
While liquid cooling offers numerous advantages, it also presents challenges, including:
System Complexity: Liquid cooling systems are more complex than air-cooled systems, requiring precise engineering and regular maintenance.
Cost: The initial investment in liquid cooling systems is higher due to the need for specialized components and installation.
Coolant Management: Ensuring the coolant remains uncontaminated and effective over time requires robust monitoring and maintenance protocols.
To address these challenges, manufacturers are developing innovative solutions such as:
Advanced Materials: Using high-performance coolants and corrosion-resistant materials to enhance system durability.
Smart Monitoring Systems: Integrating IoT-enabled sensors to monitor temperature, flow rates, and coolant quality in real-time.
Modular Designs: Creating modular liquid cooling systems that simplify installation and maintenance while reducing costs.
The Future of Liquid Cooling in EV Charging Infrastructure
As the EV market continues to grow, the demand for faster, more efficient charging solutions will rise. Liquid cooling is poised to play a pivotal role in enabling the deployment of ultra-fast charging networks capable of meeting this demand. Key trends shaping the future of liquid cooling in EV charging infrastructure include:
Integration with Renewable Energy: Coupling liquid-cooled charging stations with renewable energy sources such as solar and wind to create sustainable, high-efficiency charging hubs.
Scalability: Developing scalable liquid cooling solutions that can be adapted for various charging station configurations, from residential setups to large commercial hubs.
Standardization: Establishing industry standards for liquid cooling systems to ensure compatibility and streamline deployment across different manufacturers.
Energy Efficiency Improvements: Enhancing the energy efficiency of liquid cooling systems to minimize their environmental impact.
Conclusion
Liquid cooling is transforming the EV charging landscape by enabling high-power, ultra-fast charging stations to operate safely and efficiently. As the EV ecosystem evolves, this technology will be critical in supporting the widespread adoption of electric vehicles. By addressing current challenges and leveraging ongoing innovations, liquid cooling systems will continue to advance, paving the way for a more sustainable and electrified future.
Contact Now:info@tonecooling.com
Charging station liquid cooling Control Logic

The liquid cooling system of the charging station primarily consists of a circulating water pump, a liquid cooling plate, a radiator, an electronic fan, an electronic oil pump, and a plate heat exchanger.
The integrated liquid cooling system significantly enhances the functionality of the charging station by simplifying the design of the charging module’s air duct and reducing the overall volume of the station. Additionally, it contributes to a higher protection level for the charging pile, safeguarding it against water, dust, insects, and other environmental factors that could affect its longevity. This improvement not only decreases the maintenance frequency but also enhances the overall user experience.
The high convection heat transfer coefficient and uniform temperature distribution of the liquid cooling system simplify the design of the loop.
The side-in and side-out method is employed to ensure that each component in the loop has an equivalent flow length and convergent flow resistance, thereby promoting uniform flow distribution.
The product features a quick plug-in structure, making it modular and easy to install.
The design can be easily adapted to accommodate the requirements of various power piles.
Charging station liquid cooling System Principle
The system employs variable frequency fans and water pumps to accommodate the heat exchange requirements of the charging module under various charging conditions, thereby enhancing the energy efficiency of the system.

- At low load:
Reduce fan speed and consumption to minimize noise and energy usage.
- At high load:
Increase the fan speed, adjust the water pump speed, optimize energy efficiency, and enhance noise, vibration, and harshness (NVH) as well as durability.
- When the system experiences a leak:
When the coolant level falls below the minimum threshold, the system sends a safety warning to the main computer to prevent charging failures.
- When the water temperature is excessively high:
When the water temperature exceeds the safe threshold, an alarm will be triggered to notify the central control system to reduce the charging power, thereby ensuring the safety and reliability of the system.
- When the ambient temperature is excessively high:
If the ambient temperature is excessively high, instruct the system to decrease the charging output power.
Charging station liquid cooling Device Features
Sequence | Device | Function | Type | Protection grade | RHOS |
1 | Radiator | Air-cooled convective heat exchanger | Tube type | NA | 2 |
2 | Water pump | Charging station water cycle | AC220/DC24V | IP67 | 2 |
3 | Cold plate | IGBT heat exchanger | Welding type | NA | 2 |
4 | Fan | Forced ventilation device | AC220/DC24V | IP54 | 2 |
5 | Board replacement | Oil-water heat exchanger | Aluminum sheet metal | IP67 | 2 |
6 | controller | system controller | PCBA | IP54 | 2 |
7 | Water temperature sensor | Temperature detection | 5V DC | IP67 | 2 |
8 | Environmental temperature sensor | Temperature detection | 5V DC | IP67 | 2 |
9 | Oil pump | Charging gun fluorinated oil circulation device | DC 24V | IP67 | 2 |
10 | oil temperature sensor | Temperature detection | 5V DC | IP67 |

Charging station liquid cooling Water Circulation Pump
Compared to air-cooling systems, liquid-cooling structures significantly reduce the space required, thereby enhancing the heat transfer coefficient of the system. This compact design addresses the spatial inefficiencies associated with air duct layouts and conserves resources during the installation of charging stations.

Charging station liquid cooling Device Features
Sequence | Device | Function | Type | Protection grade | RHOS |
1 | Radiator | Air-cooled convective heat exchanger | Tube type | NA | 2 |
2 | Water pump | Charging station water cycle | AC220/DC24V | IP67 | 2 |
3 | Cold plate | IGBT heat exchanger | Welding type | NA | 2 |
4 | Fan | Forced ventilation device | AC220/DC24V | IP54 | 2 |
5 | Board replacement | Oil-water heat exchanger | Aluminum sheet metal | IP67 | 2 |
6 | controller | system controller | PCBA | IP54 | 2 |
7 | Water temperature sensor | Temperature detection | 5V DC | IP67 | 2 |
8 | Environmental temperature sensor | Temperature detection | 5V DC | IP67 | 2 |
9 | Oil pump | Charging gun fluorinated oil circulation device | DC 24V | IP67 | 2 |
10 | oil temperature sensor | Temperature detection | 5V DC | IP67 | 2 |

Charging station liquid cooling Modular takeover method

Simulation model based on the platform:
- Reserve the coolant inlet and outlet to effectively address the challenges of waterproofing and dustproofing the system.
- The charging module is compact and lightweight.
- No air duct is required, and the modular design is more straightforward.
- Adopt a quick plug installation structure to enhance efficiency and reduce process costs.
- PA12 integrated cooling pipe is designed for use in cooling systems of new energy vehicles, offering high reliability.
- Quick plug sealing guarantees consistent assembly quality.
Charging station liquid cooling Computational simulation
Angpai Liquid Cooling Module
Based on the platform simulation model, we can quickly analyze the actual performance of the system selection. This approach effectively enhances development speed and allows for the early prediction of risks. Additionally, products within the same series can be simulated and calculated on the same platform, ensuring complete parametric design and increased reliability.

The simulation system includes:
- Cabinet System Heat Exchange
- Charging Gun Heat Exchange Performance
- Oil Circuit Resistance
- Water Circuit Flow Resistance Characteristics
Charging Station Liquid Cooling: A Game-Changer for EV Infrastructure
With the rapid adoption of electric vehicles (EVs) worldwide, charging station technology is evolving to meet increasing demand. One of the critical innovations revolutionizing this space is liquid cooling systems. As EV charging stations become more powerful, delivering ultra-fast charging speeds, managing heat effectively is essential to ensure safety, efficiency, and durability. Liquid cooling technology has emerged as a robust solution to these challenges, enabling the next generation of high-performance charging stations.
The Role of Liquid Cooling in EV Charging Stations
Liquid cooling is a thermal management system that uses a liquid medium to transfer heat away from critical components. In EV charging stations, where high power outputs generate significant heat, this technology is essential. Traditional air cooling methods often fall short in maintaining optimal operating temperatures for high-power systems, especially those exceeding 150 kW.
Key Benefits of Liquid Cooling:
Enhanced Efficiency: Liquid cooling systems are highly effective at dissipating heat compared to air cooling. They allow charging stations to operate continuously at peak performance without overheating.
Compact Design: Liquid cooling enables smaller and more compact designs by reducing the need for large heat sinks or fans, making it easier to install stations in urban areas with limited space.
Increased Safety: Overheating poses risks to both hardware and users. Liquid cooling ensures stable temperatures, minimizing the chances of equipment failure or accidents.
Support for Ultra-Fast Charging: With the growing demand for charging stations that deliver power outputs of 350 kW or more, liquid cooling becomes indispensable for handling the heat generated during ultra-fast charging sessions.
How Liquid Cooling Works
The process of liquid cooling involves circulating a coolant—a specially formulated liquid with high thermal conductivity—through a network of pipes and heat exchangers within the charging station. Key components of a liquid cooling system include:
Coolant Pump: Circulates the liquid through the system.
Heat Exchanger: Transfers heat from the components to the coolant.
Radiator: Dissipates heat from the coolant into the surrounding environment.
Temperature Sensors: Monitor and regulate the system to ensure optimal performance.
The coolant absorbs heat from high-temperature components, such as charging cables and power converters, and transfers it to the radiator, where it is released into the air. This closed-loop system ensures efficient heat management even during high-demand usage.
Applications in High-Power Charging Stations
Liquid cooling systems are particularly vital for high-power charging stations designed for ultra-fast charging. Such stations are equipped with high-capacity power modules and advanced charging cables capable of delivering large amounts of energy in a short time. However, this level of performance generates significant heat, which can degrade components or reduce efficiency if not properly managed.
For example, ultra-fast charging cables often require active cooling to maintain safe operating temperatures. Liquid-cooled cables, which integrate cooling channels within the cable structure, ensure that heat is effectively dissipated, enabling users to charge their vehicles safely and quickly without overheating the equipment.
Challenges and Innovations
While liquid cooling offers numerous advantages, it also presents challenges, including:
System Complexity: Liquid cooling systems are more complex than air-cooled systems, requiring precise engineering and regular maintenance.
Cost: The initial investment in liquid cooling systems is higher due to the need for specialized components and installation.
Coolant Management: Ensuring the coolant remains uncontaminated and effective over time requires robust monitoring and maintenance protocols.
To address these challenges, manufacturers are developing innovative solutions such as:
Advanced Materials: Using high-performance coolants and corrosion-resistant materials to enhance system durability.
Smart Monitoring Systems: Integrating IoT-enabled sensors to monitor temperature, flow rates, and coolant quality in real-time.
Modular Designs: Creating modular liquid cooling systems that simplify installation and maintenance while reducing costs.
The Future of Liquid Cooling in EV Charging Infrastructure
As the EV market continues to grow, the demand for faster, more efficient charging solutions will rise. Liquid cooling is poised to play a pivotal role in enabling the deployment of ultra-fast charging networks capable of meeting this demand. Key trends shaping the future of liquid cooling in EV charging infrastructure include:
Integration with Renewable Energy: Coupling liquid-cooled charging stations with renewable energy sources such as solar and wind to create sustainable, high-efficiency charging hubs.
Scalability: Developing scalable liquid cooling solutions that can be adapted for various charging station configurations, from residential setups to large commercial hubs.
Standardization: Establishing industry standards for liquid cooling systems to ensure compatibility and streamline deployment across different manufacturers.
Energy Efficiency Improvements: Enhancing the energy efficiency of liquid cooling systems to minimize their environmental impact.
Conclusion
Liquid cooling is transforming the EV charging landscape by enabling high-power, ultra-fast charging stations to operate safely and efficiently. As the EV ecosystem evolves, this technology will be critical in supporting the widespread adoption of electric vehicles. By addressing current challenges and leveraging ongoing innovations, liquid cooling systems will continue to advance, paving the way for a more sustainable and electrified future.
Contact Now:info@tonecooling.com