Simplified Method and Application of Thermal Model for High-Power DC Charging Modules

doi:10.16628/j.cnki.2095-8188.2026.02.009

Abstract

Abstract:

With the continuous improvement of the power level and power density of high-power DC charging modules, more severe challenges are posed to the heat dissipation design of modules, among which forced air cooling heat dissipation is widely used in high-power DC charging modules.First of all, the overall hydrodynamic modeling of the module inlet section and fully developed section is carried out to obtain a unified mathematical model.On this basis, the impedance characteristic curve of the system is obtained and then associated with the static pressure drop of the fan to determine the working point of the system and mathematically model the thermal resistance of radiator.A simplified design method of the thermal model is proposed, based on which a 60 kW high-power DC charging module with forced air-cooling heat dissipation is constructed, and the reasonableness and feasibility of the modeling and simplified design are verified through finite element simulation and thermal experiment.

Key words: DC charging module, fluid dynamics modeling, thermal resistance of radiator, forced air cooling, simplified method

CLC Number:

TM910.6

YAO Zepeng, HUANG Ju, ZHOU Junhui, ZHENG Zonghua, MAO Xingkui. Simplified Method and Application of Thermal Model for High-Power DC Charging Modules[J]. LOW VOLTAGE APPARATUS, 2026, 0(2): 67-76.

Figures/Tables 13

References 16

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风扇型号(恒泰)	高度/ mm	厚度/ mm	最大静压/ Pa	最大风量/ (m³·s^-1)
DA08025B12S	80	25	276	0.047 1
DA08032B12U	80	32	220	0.037 6
DZ08038B12U	80	38	286	0.046 3
DF08038B12V	80	38	646	0.051 3

器件	单个尺寸(长度×宽度×高度)/mm
共模电感	80×80×50
PFC电感	80×72×45
散热器	85×15×45
母线电容	35×35×45

参数	仿真数值	实验结果
散热器热阻/(℃·W^-1)	0.032 5	0.034 7
散热器表面最大温升/℃	27.3	29.2
功率器件壳温最大温升/℃	47.3	48.7