Liquid Cooling Solution for Ultra-Fast EV Charging Systems
Magnetic Gear Pump Solution for Charging Cable Cooling (Chenhui MPB075 & MPB150 Series)
1. Application Background: The Rise of Liquid-Cooled Ultra-Fast Charging
With the rapid growth of electric vehicles (EVs), ultra-fast charging stations (600kW–1MW+) are becoming the new standard in charging infrastructure.
At such high power levels, EV charging cables generate significant heat during continuous operation. Without efficient cooling, this can lead to:
- Charging power derating
- Overheating of charging cables and connectors
- Reduced charging efficiency
- Safety protection shutdowns
To solve this, modern systems adopt liquid-cooled charging cable technology, which requires a highly reliable circulation pump as the core component.
👉 The magnetic gear pump has become the preferred solution for stable and safe coolant circulation in ultra-fast EV charging systems.
2. Key Challenges in Liquid-Cooled EV Charging Systems
Liquid cooling systems for EV fast charging face strict technical requirements:
2.1 Continuous High-Load Operation
Charging stations operate 24/7 and require pumps capable of long-term continuous duty.
2.2 Stable Flow Control for Thermal Consistency
Any flow fluctuation may cause:
- Uneven cable temperature
- Reduced cooling efficiency
- Automatic power reduction
2.3 Zero-Leakage Requirement for Electrical Safety
Coolants (glycol-water mixtures or dielectric fluids) must remain fully sealed to prevent:
- Electrical hazards
- System contamination
- Maintenance issues
2.4 Outdoor Environmental Reliability
Charging stations must operate under:
- Temperature fluctuations
- Vibration and mechanical stress
- Dust and harsh environments
3. The Solution: Magnetic Gear Pump Liquid Cooling System
A magnetic drive gear pump uses a non-contact magnetic coupling to transmit torque between the motor and pump shaft.
This eliminates the need for a mechanical seal and provides a fully sealed fluid system.
Core system features:
- Seal-less magnetic drive design
- Fully enclosed coolant circulation loop
- Precision gear-based positive displacement
- High-reliability torque transmission
👉 Delivering a truly zero-leakage liquid cooling solution for EV charging systems.
4. Product Solution: Chenhui MPB075 & MPB150 Series
To meet different power levels of ultra-fast charging systems, Chenhui offers two high-performance magnetic gear pump solutions:
■ MPB075 Series Magnetic Gear Pump
Ideal for medium to high-power charging systems
Key features:
- Stable low-pulsation flow output
- Compact structure for easy integration
- High reliability magnetic coupling system
- Continuous duty operation capability
Typical applications:
- 400kW–600kW EV fast charging systems
- Single-gun liquid cooling modules
- Auxiliary cooling circulation systems
■ MPB150 Series Magnetic Gear Pump
Designed for high-power ultra-fast charging stations
Key features:
- Higher flow rate and pressure capability
- Reinforced magnetic drive structure
- Stable performance under heavy continuous load
- Excellent thermal management support
Typical applications:
- 600kW–1MW+ ultra-fast charging stations
- Multi-gun charging systems
- High-density charging hubs
- Centralized thermal management systems
5. Working Principle in Charging Cable Cooling Systems
In a liquid-cooled EV charging system, the MPB075 / MPB150 pump performs continuous coolant circulation:
- Motor drives external magnetic rotor
- Magnetic coupling transfers torque to internal rotor
- Precision gears generate volumetric fluid flow
- Coolant circulates through closed-loop cooling channels
- Heat from charging cable is continuously removed via heat exchanger
👉 Ensuring stable temperature control, continuous cooling, and leak-free operation.
6. Key Advantages of Chenhui Magnetic Gear Pumps
✔ 6.1 Zero-Leakage Design for Maximum Electrical Safety
The seal-less magnetic coupling structure eliminates leakage risks, making it ideal for:
- High-voltage EV charging environments
- Outdoor charging infrastructure
- Unmanned operation stations
✔ 6.2 Stable Flow Output for Consistent Cable Temperature
Positive displacement gear design ensures:
- Stable coolant circulation
- Uniform cable temperature distribution
- Prevention of thermal derating
✔ 6.3 Full Coverage with MPB075 & MPB150 Series
Two-product platform supports full range applications:
- MPB075: Modular and compact cooling integration
- MPB150: High-power centralized cooling systems
✔ 6.4 24/7 Continuous Operation Capability
Designed for high-duty EV charging environments:
- Long service life
- Low wear magnetic structure
- Minimal maintenance requirements
✔ 6.5 Wide Compatibility with Cooling Fluids
Supports common EV thermal management fluids:
- Ethylene glycol-water mixtures
- Deionized water
- Industrial thermal transfer fluids
7. Application Scenarios
Chenhui MPB075 & MPB150 magnetic gear pumps are widely used in:
- 600kW / 800kW / 1MW+ ultra-fast EV charging stations
- Liquid-cooled charging cable systems
- EV charging cabinet thermal management units
- Multi-gun fast charging hubs
- EV infrastructure cooling systems
8. Industry Trend: From Air Cooling to Full Liquid Cooling Systems
The EV charging industry is rapidly evolving toward:
- Air cooling → Hybrid cooling → Full liquid cooling
- Low power charging → Ultra-fast charging
- Distributed cooling → Centralized thermal management
In this transformation, high-reliability circulation pumps are becoming a core component of EV charging infrastructure.
Magnetic gear pumps, especially MPB075 and MPB150 series, are emerging as key enabling technology for next-generation ultra-fast charging systems.
9. Conclusion: Enabling Reliable Thermal Management for Ultra-Fast Charging
The Chenhui MPB075 and MPB150 magnetic gear pump series provide a robust and scalable solution for liquid-cooled EV charging systems.
Key benefits include:
- Zero-leakage operation for maximum safety
- Stable and precise coolant flow control
- Long service life for 24/7 operation
- Scalable solutions for different power levels
👉 A critical enabling component for the future of high-power, high-reliability EV charging infrastructure.