Multi-Physical Field Simulation Study on Variable Cooling Cross-Section of Overcharged Cables

With the continuous development of new energy vehicle technology and the increasing demand for fast charging, the thermal effect generated during the charging process has become one of the important factors restricting the charging speed of electric vehicles. To address this issue, this study proposes to establish a finite element simulation model for electromagnetic, thermal, and fluid dynamics multi-physics coupling of supercharged liquid cooled cables. The influence of different structural parameters of the liquid cooled channel on the temperature and current carrying capacity of the cable core for charging in the supercharging scenario was compared and analyzed, without changing the cross-sectional area and ambient temperature of the cable core. The simulation results show that the cross-sectional area of the cooling channel has the greatest impact on the temperature and current carrying capacity of the charging cable conductor. When the cross-sectional area of the cable core is 70mm2, the coolant flow rate is 0.1m/s, the cooling medium is ethylene glycol aqueous solution, and the ratio of the cross-sectional area of the cooling channel to the cable core is 1.25, the current carrying capacity of the charging cable reaches 600A, and the temperature is 49.7 °C. The research provides a more comprehensive and in-depth theoretical basis for the design and optimization of overcharged cables, and provides useful references for the further development of electric vehicle charging technology.