Structure and operation mechanism of liquid-cooled fast charging gun

NexwayEV's liquid-cooled rapid charging solution strictly follows the GB/T 20234 interface specification and incorporates the CCS Connector for rapid charging layout to ensure compatibility with global mainstream models and enhance the international charging experience.

Liquid Cooling System Composition and Working Mechanism

NexwayEV's liquid-cooled charging gun system relies on an electronic circulation pump to continuously circulate coolant in a closed channel. The coolant absorbs the heat generated by the high current transfer as it passes through the charging cables and is then directed to the cooling module to dissipate the heat. This reciprocating process ensures that the system remains cool under high charging loads and supports the high currents carried by the fine cross-section conductors.

Product technical highlights

1. modern design of gun body, comfortable and convenient operation, modular structure is convenient for later assembly and maintenance;

2. one-button closure design with integrated electronic lock to enhance operational safety;

3. Strong protection ability, the protection level of the outlet end reaches IP67. 4;

4. Multiple wire diameters to suit various charging power requirements:

Φ24mm corresponds to rated 500A

Φ28mm corresponds to rated 600A

Φ30.5mm can reach 700A.

5. Equipped with emergency manual release mechanism, supporting manual unlocking in case of sudden power failure or abnormal state;

6. independent liquid-cooled component structure, equipped with a temperature sensing system, capable of real-time monitoring of the thermal state of the contact area;

7. cable connection using ultrasonic welding process, compared with the traditional crimping method has a lower contact resistance, to ensure higher transmission efficiency.

Electrical Performance Parameters

1. Rated current range covers:

500A (Φ24 cable)

600A (Φ28 cable)

700A (Φ30.5 cable)

2. Rated voltage: 1000V DC

Innovative Cooling Structure Solution

NexwayEV adopts a patented cooling chamber structure, which directs the coolant to the high-current terminal insertion area and builds multiple cooling paths to ensure that the thermal fluid forms a stable circulation channel between the inside and outside of the system, thus improving the overall cooling efficiency. This structure seamlessly integrates with the CCS fast charging interface design to ensure that the system temperature is always controlled during high power transmission.

Low Resistance Connection Technology

During high current charging, the contact resistance between the terminals and cables has a significant impact on the cooling efficiency of the system. For this reason, NexwayEV recommends the use of ultrasonic welding technology for cable termination, which effectively avoids the mechanical loosening and increased internal resistance caused by the traditional crimping process during hot and cold cycles. In addition, this method can further optimize the conduction performance and reduce energy loss.