Views: 95 Author: Site Editor Publish Time: 2024-09-24 Origin: Tonhe Technology
As the demand for electric vehicles (EVs) continues to rise, the reliability and efficiency of EV charging stations become increasingly important. Central to the performance of these charging stations is the EV power module, a crucial component that governs the flow and conversion of electrical energy. The durability of the EV power module plays a significant role in determining the overall lifespan and reliability of EV chargers. In this article, we will explore how improvements in power module durability can extend the operational life of EV chargers, enhance performance, and reduce maintenance costs.
An EV power module is responsible for converting alternating current (AC) from the grid into direct current (DC) to charge EV batteries. These power modules regulate voltage, manage current flow, and ensure the safe and efficient transfer of energy. Given the high voltages and currents involved in fast-charging applications, the EV power module is subjected to significant stress, particularly in high-power charging stations where performance is critical.
Without a durable EV power module, the efficiency and lifespan of the charging station can suffer, leading to increased downtime, costly repairs, and a diminished user experience. As such, enhancing the durability of the EV power module is essential for ensuring the long-term success of EV charging infrastructure.
The durability of an EV power module is influenced by several factors, including radiating and environmental conditions. Fluctuations in voltage and current, especially in fast-charging scenarios, can strain the components of the EV power module over time. Environmental factors such as humidity, dust, and temperature variations also impact the longevity of power modules, particularly in outdoor charging stations.
Frequent use of EV chargers also increases wear and tear on the EV power module, accelerating the rate of degradation. Therefore, ensuring the durability of power modules is critical for maintaining the reliability and operational efficiency of EV chargers.
To enhance module environmental adaptability, Tonhe Technology has been promoting a dual gel-filling solution in the industry since 2021, suitable for harsh environments such as salt spray and dust. Using a fully automated gel-filling production line, Tonhe applies silicone rubber with good adhesion around the PCB perimeter, followed by flowable organic silicone gel covering the entire PCB, achieving a potting thickness of 2.5mm. This gel-filling solution by Tonhe Technology meets over 99% of on-site usage scenarios through simulated harsh environmental conditions (considering dust particle size, conductivity, acidity and alkalinity) and over two years of on-site validation.
Tonhe Technology Gel-filling Power Module
Tonhe Technology Gel-filling Power Module
Recent advancements in technology have greatly improved the durability of the EV power module, leading to longer-lasting and more reliable charging stations. Silicon carbide (SiC) components are now being used to enhance the thermal and electrical capabilities of power modules. These materials offer higher thermal conductivity, better voltage tolerance, and greater efficiency, making them more resistant to the stresses encountered during high-power charging.
In addition to improved components, advanced cooling solutions such as liquid cooling systems are being implemented to manage the heat generated by the EV power module. These innovations help prevent overheating and thermal fatigue, extending the operational life of the power modules and reducing the likelihood of failure.
TH40F10030C8L-WT is a liquid cooled power module with high efficiency and high power density developed by Tonhe Technology for charging pile. It supports 323Vac ~ 460Vac three-phase four-wire system (three-phase +PE) input, the maximum power is 40kW, and the default constant output power range is 300Vdc ~ 1000Vdc. The monitoring unit/control unit of the charging system CAN communicate with the power module through the CAN bus. Based on the communication, the functions of working parameter setting, operating parameter collection and working state control of the power module can be realized.
TH40F10030C8L-WT
TH40F10030C8L-WT
Impact on EV Charger Lifespan
The durability of the EV power module directly affects the lifespan of EV chargers. More robust power modules reduce the frequency of repairs and replacements, lowering maintenance costs and minimizing downtime. This ensures that charging stations remain operational for longer periods, providing a more reliable service to EV drivers.
In addition, durable power modules enhance the safety of EV chargers by reducing the risk of overheating and electrical failure. For operators of charging networks, this translates to fewer liabilities and a more stable, efficient infrastructure.
The EV power module is a critical component in determining the reliability and longevity of electric vehicle chargers. By improving the durability of these power modules through innovative technical design and thermal management solutions, the lifespan of EV chargers can be significantly extended. As EV adoption grows, investing in durable and efficient power modules will be essential for supporting the expanding charging infrastructure and ensuring the long-term success of electric transportation.
For more information on Tonhe Technology, visit our official website(www.tonhetech.com) or contact our sales team(info@sjzthdz.com). Whether you are planning a new installation or upgrading an existing system, Tonhe Technology has the expertise and solutions to ensure your success.
