As the “fuel stations” for electric vehicles, the charging times for EV chargers are considerably longer compared to traditional refueling. With sales of new energy vehicles continuing to rise, concerns over battery life and the availability of charging stations—especially during peak periods like holidays—are becoming more common. The viral news story about a Tesla driver stuck in traffic during the recent National Holiday, unable to reach a charging station and requiring a tow truck due to an empty battery, sparked widespread discussion.

Compared to the sluggish charging speeds of “low-flow” chargers, fast-charging EV chargers are much more attractive to consumers. To keep up with the increasing demand for faster charging, the output power of EV chargers must be scaled up, which in turn raises the heat flow density within the system. This presents significant challenges to the safety and efficiency of the charging system.

A crucial solution to this issue is the use of liquid cooled EV charger pumps. When manufacturers choose water pumps for their new energy vehicle charging piles, they must ensure that the pump maintains high reliability, long service life, quiet operation, and resistance to water and dust in extreme temperatures (ranging from -45°C to 80°C). It should also provide multiple safety protections and intelligent controls.

The role of  EV fast charger pumps in electric vehicle charging systems can be broken down into two main areas:

–Liquid Cooling Modules
In the DC fast-charging system, the liquid cooling circuit consists of several cooling modules. A circulating pump and a diverting valve are used to distribute coolant evenly across these modules. The design of the internal pipes in the cooling module depends on the position of the heating components in the charging pile, with the coolant circulating through cold plates to absorb and dissipate heat.

–Liquid-Cooled Charging Cables
These specialized cables are designed to handle high-current charging applications. A cooling channel runs between the cable and charging gun, with coolant circulating to absorb heat. The liquid cooled EV charger pump drives this circulation, efficiently removing excess heat from the system. For example, Tesla’s V3 supercharger, introduced in March 2019, uses a liquid-cooled charging cable that is about 44% smaller in diameter than its V2 counterpart (23.87mm). This upgrade allows the V3 supercharger to deliver a maximum peak power of 250kW.

The EV charger cooling pump is essential for managing the heat dissipation needs of high-power chargers, minimizing heat-related damage to components such as the charging gun, cable, and charging pile.

TOPSFLO has been a leader in the development of cooling systems for charging piles. The company’s DC EV charger pumps offer numerous advantages over standard pumps, including compact size, excellent cooling performance, resistance to both high and low temperatures, long lifespan, and maintenance-free operation. Additionally, these pumps are designed with intelligent control systems and can be customized to meet specific customer requirements, including electromagnetic compatibility (EMC) solutions.

Each liquid cooled  fast EV charger pump by TOPSFLO undergoes comprehensive high and low-temperature fast-switching tests, ensuring that it performs reliably in the extreme conditions of supercharging stations. TOPSFLO pumps use high-quality electronic components from renowned international brands, ensuring reduced heat generation and exceptional reliability. Additionally, TOPSFLO’s brushless DC charging pile pumps feature 5V/PWM speed regulation and FG feedback signals, allowing for automatic detection, real-time data feedback, and failure alarms to protect high-performance liquid cooling systems in supercharging piles.

As a vital part of the new energy vehicle infrastructure, charging piles have gained significant national policy support and are growing rapidly in response to rising market demand. With nearly 20 years of expertise, TOPSFLO focuses on the development and manufacturing of brushless DC water pumps, leveraging cutting-edge technology to support the global shift toward electric and intelligent vehicles, and driving innovation in the development of liquid cooled EV charger pumps.