DC EV charging structural design

As the key energy supply facility for electric vehicles, the structural design of charging piles is also particularly important. This article mainly focuses on the theme of DC EV charger design and issues that need attention.

DC EV charger design mainly takes the cabinet as the main body. The charging pile is divided into: AC input block, charging module block, high voltage output block, and controller block.

The following issues need to be considered in the structural design of the charging module:

1. It is necessary to consider the weight of the module and whether the frame can bear its weight.

When there are multiple modules and heavyweight, 3.0mm cold-rolled plates are usually used as the load-bearing material of the module body,

and the rationality of its structure is analyzed with finite element analysis to avoid load-bearing frame breakage during transportation.

2. The rationality of the air duct needs to be considered.

The design of the module room must ensure that the air inlet and outlet of the module are two chambers and are not ventilated with other chambers.

The wiring of the module can be connected to other chambers using rubber sheaths to ensure the sealing of the chamber.

In this way, under the action of the fan, the air outlet will generate negative pressure and extract the air from the air inlet,

thereby improving the heat dissipation efficiency of the module and extending the service life of the charging pile.

DC EV charging cabinet structure diagram

AC input, DC output, control board, and high-voltage output are all components integrated components. They are usually installed on an aluminum-zinc-coated/galvanized board. When designing the mounting boards of these modules, we need to consider the components. Regarding layout issues, reasonable layout planning can greatly improve the efficiency of employees in wiring and facilitate later maintenance.

3. Installation problem of the component mounting plate.

The process of installing the sheet metal into the cabinet was not simulated in the design. As a result, after production was completed, it was found that the mounting plate could not be installed into the cabinet normally. To address this problem, three-dimensional design software can be used to make full use of the movement characteristics of the assembly’s coordination relationship to simulate many problems that may occur during the installation process of physical objects, effectively avoiding many problems that may occur during installation.

DC EV charging overall structure diagram

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