Views: 9741 Author: Site Editor Publish Time: 2024-12-24 Origin: Tonhe Technology
Tonhe Technology has launched a groundbreaking new product, the TH40F10030C8 charging module, which boasts an impressive power density of 78W/in⊃3;, breaking through industry technological bottlenecks.
As is well known, the increase in power density is directly linked to a reduction in the cost per unit of power, making high power density a key focus for many charging module manufacturers. However, there is a so-called "barrel effect" in module design, where the overall performance is limited by the weakest component, especially its temperature constraints. Therefore, the key breakthrough in advancing high power density technology has always focused on achieving uniform heat dissipation.
According to the analysis results of thermal simulation tests, if the commonly used three-fan 40kW solution on the market is simplified to a two-fan configuration, it will fail to ensure proper heat dissipation. This simplification not only leads to significant power derating but also shortens the lifespan of the equipment.
Tonhe Technology has successfully overcome industry bottlenecks by adopting flexible applications of silicon carbide (SiC) power devices, innovative designs for magnetic components, and optimizing the overall heat dissipation structure. This technological advancement has increased the power density from the industry standard of 60W/in⊃3; to 78W/in⊃3;, a 30% increase, significantly enhancing the product's cost-effectiveness. This is both a breakthrough in performance and in value.
Tonhe Technology's Taihang Series 40kW charging module fully meets the key focus areas of this standard, taking practical usage scenarios into account. It addresses commonly used voltage points of 400V, 600V, and 800V, as well as load rates from 20% to 100%. Compared to mainstream market products, the weighted efficiency is improved by 2%.
According to surveys, a battery swapping station needs to swap over 4,000 kWh per day to reach breakeven. By using the Taihang Series 40kW modules, approximately 89 kWh of electricity can be saved daily, resulting in an annual electricity savings of over 30,000 kWh.
Reliability is the fundamental requirement for any industrial product. With the current return-on-investment period for battery swapping stations being over 5 years, it is essential that the charging modules have a longer service life.
Leveraging over twenty years of experience in designing various power supplies, Tonhe Technology has determined that a potting solution is more suitable for charging modules. Traditional three-proofing and dispensing solutions only provide partial protection. After prolonged outdoor operation, traditional solutions present the following risks:
The three-proof coating cannot cover the sharp edges of components, and some component leads are missed due to obstructions like heat sinks.
The lifespan of the three-proof coating is limited. Over time, salt mist can penetrate the interior as the coating ages.
Dispensing cannot cover all surface-mounted components, especially those obstructed by heat sinks, such as copper foils.
In 2021, Tonhe Technology introduced a dual-sided gel-filling solution to the industry, designed for harsh environmental conditions. The solution uses high-viscosity silicone to encase the perimeter of the PCB, and then applies a more fluid silicone gel to cover the entire PCB, with a gel-filling thickness of 2.5mm. The solution incorporates fully automated dual-sided gel-filling technology, including a DSP control board.
The fully automated gel-filling production line we introduced, compared to the manual or semi-automated gel-filling methods commonly used in the industry, significantly reduces the risk of PCB failure during the manufacturing process (such as PCB deformation during handling or inconsistent potting thickness affecting heat dissipation). This also improves production efficiency and ensures product consistency.
It is commonly believed that a higher IP rating means higher reliability. However, if we reverse this thinking, does pursuing higher reliability necessarily require a higher IP rating? Similarly, does a module with a direct air ventilation heat dissipation design inherently have lower reliability?
Over the past three years, Tonhe Technology has continuously conducted in-depth research and optimization of its dual-sided gel-filling technology. In the early stages of development, our products were already able to withstand various harsh field application environments, including simulated conductive dust, salt mist, alternating damp heat, and long-term accelerated aging under extreme conditions. After undergoing these extreme tests, the modules were still able to maintain stable operation during final power-on tests. Additionally, we conducted rigorous testing of the insulation resistance across different channels, and the results showed that the performance far exceeded the standard requirements.
Through further optimization, we have achieved the ability to provide special protection for the module connectors. After briefly submerging the entire module in water and then removing it, the module is still able to operate normally when powered on.
Our latest progress is that the module can now operate directly while submerged in water (due to heat dissipation issues, it cannot run for extended periods).
High protection without increasing costs!
High protection without increasing size!
High protection without additional cabinet design!
This is the new benchmark for extreme protection created by Tonhe Technology!
While pursuing high product reliability, Tonhe Technology continues to drive technological innovation and implement a differentiated strategy to meet the growing and diverse application needs of users. The company will continuously introduce high-performance, high-quality products, committed to providing global users with more efficient and reliable Tonhe solutions.
