TITLE:
Design of Helical-Grooved Pipes for Direct-Immersion Liquid-Cooled Ultra-Fast Charging Cables
AUTHORS:
Shupeng Zhao, Ye Zhao, Qunxia Sun, Yanrong Ni, Qihan Li, Haosong Sun, Feng Tian, Liujie Wan, Xiaohe Zhao
KEYWORDS:
Super Fast Charging Cable, Liquid Cooling, Heat Dissipation, Liquid Cooling Pipeline
JOURNAL NAME:
World Journal of Engineering and Technology,
Vol.13 No.4,
November
27,
2025
ABSTRACT: Direct-immersion liquid-cooled charging cables, which feature high heat dissipation efficiency, have a wide range of application in pile-side electrical connections of high-power mobile charging equipment. However, the power line conductors in the cable may deviate from the center of the liquid-cooled pipes under external forces, since the power line conductors are only fixed by rigid connection components at both ends, during use. This will result in uneven heat distribution on the cross-section of the coolant pipes, leading to local thermal aging of the pipes and thus reducing the service life of the cables. To address this issue, a liquid-cooled pipe model with internal helical-grooved channels was proposed in this paper, which utilizes its geometric structure to induce transverse liquid flow and enhance heat transfer. COMSOL Multiphysics was employed for the simulation calculation. The results showed that the liquid-cooled pipeline with an internal spiral groove can effectively improve the lateral temperature uniformity when the power line is eccentric by improving the fluid motion shape. This achievement provides theoretical support and a technical path for efficient thermal management of high-power charging station cables.