Automotive Engineering - March 2022 - 9

TECHNOLOGY REPORT
Level 1 (120 V), Level 2 (240 V) or Level
3 (DC fast) charger is used. The main
influencers for charging times are the
EV battery's power input rating, the
power supply's output rating, and the
charging cable. A sub-five-minute
charge time would require that the
power ratings and charging cable be
rated at 2,500 A.
Commercially available charging station
cables are liquid-cooled, using the
principle of forced convection heat
transfer, noted Devahdhanush. In this
conventional cooling technique, fluid
absorbs heat from the cable. After the
heat is dissipated to the external surroundings,
the fluid temperature falls
and the cooling cycle continues.
The Purdue cable design incorporates
a liquid-to-vapor cooling process. A
dielectric heat transfer fluid flows within
the cable conduit that surrounds the
wires. When the wires' surface temperature
becomes greater than the fluid's
boiling point, the liquid starts boiling at
the wire surface and small vapor bubbles
are produced.
Purdue University's charging station
cable R&D team, led by mechanical
engineering professor Dr. Issam
Mudawar, regularly communicates with
a team of Ford Motor Co. researchers
to review findings and provide feedback
on various focus areas. Michael
Professor Issam Mudawar (center) leads a Purdue University team working to develop a new
charging station cable inside the Boiling and Two-Phase Flow Laboratory at Purdue's School of
Mechanical Engineering.
Degner, senior technical leader at Ford
Research and Advanced Engineering,
noted that this research alliance has
the potential to make EV and commercial
fleet ownership considerably more
appealing and accessible.
The next steps in the project include
testing the innovative charging station
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March 2022 9
cable on EVs. " We are now negotiating
with several cable, coupler, pump, and
heat exchanger vendors as part of our
just-announced Research Center for
Electric Vehicle Charging and Thermal
Management to determine how to commence
such testing, " Devahdhanush said.
Kami Buchholz
JARED PIKE
http://info.hotims.com/82330-706

Automotive Engineering - March 2022

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