Research on a Forced Air Cooling Technique for Charging Guns

To address the problems of excessive temperature rise in high-power naturally cooled charging guns and the limited application scenarios due to the short length of liquid-cooled cables, this paper proposes a heat dissipation design scheme for a charging gun based on forced air cooling with an independent air duct. Taking a charging gun used on a 400 kW (400 A/1000 V DC) high-power charging station as an example, this study investigates a forced air cooling system and analyzes the effects of factors such as fan installation position and airflow direction on the heat dissipation performance of high-power charging guns. Through comparative analysis of theoretical simulation and experimental validation, the results demonstrate that the heat dissipation performance of the forced air-cooled charging gun is significantly superior to that of the naturally cooled charging gun. The optimal cooling effect is achieved when the fan operates in suction mode and is installed directly below the power pins. The proposed forced air cooling scheme can significantly enhance the current-carrying capacity and operational safety of the charging gun, providing valuable insights for the thermal design of high-power-density charging guns.