Numerical Study on Water-in-copper of High Power Electric Vehicle Charging Cable Assemblies

DONG Chen; MA Yanhua; WANG Ke; ZHANG Wei; YE Jiande

doi:10.13296/j.1001-1609.hva.2026.05.019

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Numerical Study on Water-in-copper of High Power Electric Vehicle Charging Cable Assemblies

Research & Analysis | 更新时间：2026-05-13

- Numerical Study on Water-in-copper of High Power Electric Vehicle Charging Cable Assemblies
- High Voltage Apparatus Vol. 62, Issue 5, Pages: 166-174(2026)
- 作者机构：
  
  国网电力科学研究院有限公司，南京 200116
- 作者简介：
- 基金信息：
- DOI：10.13296/j.1001-1609.hva.2026.05.019
  CLC：
- Received：01 October 2025，
  
  Revised：2025-12-20，
  
  Published：16 May 2026
- 稿件说明：
移动端阅览
DONG Chen, MA Yanhua, WANG Ke, et al. Numerical Study on Water-in-copper of High Power Electric Vehicle Charging Cable Assemblies[J]. High Voltage Apparatus, 2026, 62(5): 166-174.
DOI：

DONG Chen, MA Yanhua, WANG Ke, et al. Numerical Study on Water-in-copper of High Power Electric Vehicle Charging Cable Assemblies[J]. High Voltage Apparatus, 2026, 62(5): 166-174. DOI： 10.13296/j.1001-1609.hva.2026.05.019.

摘要

电动汽车在大功率充电时，充电电缆会承受较大的电流，同时产生大量的热量，热量的不断聚集会导致温度逐步上升从而引发安全问题。为解决此问题，提出了直接接触的“水包铜”的冷却方案，利用Comsol Multiphysics有限元分析软件，建立了充电电缆组件的三维电—热—流耦合模型，研究流道间隙，入口流速以及入口温度对电缆组件温度分布的影响。结果表明：随着流道间隙的增加，各部件的温度降低，流体的平均温度与导体中心温度沿轴向增加，在轴向距离0～75 mm内导体中心温度差异不大；随着入口流速的增加，各部件的温度降低，流体的平均温度与导体中心温度沿轴向增加；随着入口温度的增加，各部件的最高温度呈线性增大，流体平均温度与导体中心温度沿轴向升高且速率相同。

Abstract

In case of high-power chaging for electric vehicles

the charging cable carries a high current and

at the same time

generates a significant amount of heat. The continuous accumulation of the heat will lead to the gradual rise of temperature

thus causing safety issues. For solving the problem

a direct contact‘water copper-in-cooper' cooling schems is proposed. A three-dimensional electric-thermal-fluid coupling model of the charging cable assemblies is set up by using Comsol Multiphysics finite element analysis software so to study the influence of channel gap

inlet velocity and inlet temperature on the temperature distribution of the cable assemblies. The results show that with the increase of the channel gap

the temperature of each part decreases

the average temperature of the fluid and of the center of conductor increases along the axial direction

and the temperature of the center of the conductor has little difference within the axial distance of 0-75 mm. With the increase of the inlet velocity

the temperature of each part decreases

and the average temperature of the fluid and of the center of the conductor increases along the axial direction. With the increase of the inlet temperature

the maximum temperature of each part increases linearly

and the average temperature of the fluid and the temperature of the center of the conductor increase at the same rate along the axial direction.

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references

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