Cooling e-charging station components and battery storage system

Public charging stations for electric vehicles are complex systems. These include power electronics, control units and safety mechanisms that monitor and regulate the charging process. The power electronics in particular, which are responsible for converting and controlling the flow of electricity, generate a lot of heat. These power transistors and thyristors therefore require efficient cooling in order to ensure safe and optimal "refuelling". EKL develops and produces cooling systems specially designed for these applications. Our product range extends from air-cooled high-performance heat sinks to liquid cooling to dissipate the heat generated and maintain the performance of the charging station even at high ambient temperatures.

One of the key components of a wallbox for charging electric cars is phase current detection, which ensures that none of the three current phases is overloaded. The Electric Vehicle Charge Controller (EVCC), which controls the communication between the vehicle and the EV wallbox, monitors the charging process. Some of these components, especially those connected to the power electronics, require cooling. Heat sinks from EKL prevent overheating in the wallbox for electric cars, ensure consistent efficiency in the charging process and extend the service life of your wallbox product.

Batteries are essential for storing electricity in electric cars and buildings - and they are expensive. Battery management systems (BMS) are the centrepiece of modern battery technology, as they protect the investment in battery storage systems by ensuring constant performance, safety and a long service life. Sensors collect data on voltage, current and temperature to ensure optimal battery performance. Switches play a critical role by making or breaking the connection between the battery, load and charger. Microcontrollers process the collected data and execute complex algorithms to control and monitor the battery. This also includes preconditioning, i.e. cooling or heating the solar storage tanks to the optimum charging temperature. Communication modules transmit the collected data to other systems. Displays provide users with important information about the battery status.
Power switches and converters in particular, which switch high currents and adjust voltages, generate significant power losses. Power semiconductors such as transistors and diodes used in these components are particularly susceptible to overheating.
Heat sinks, fans or liquid cooling systems from EKL are an integral part of a BMS to ensure a stable operating temperature and ensure the longevity and reliability of the battery.

Charging plugs such as the type 2 for electric cars have the task of converting the alternating current from the power grid into direct current via an integrated rectifier, which is then stored in the vehicle's high-voltage battery. These components must be cooled during the charging process, especially the power electronics of the AC/DC converter. For the charging control of electric vehicles at household sockets, the in-cable control box performs safety and communication functions so as not to overload the household socket. The high currents generate heat in the electronic components. EKL offers thermal management using heat sinks to protect your components from overheating even at peak loads.