Air Duct Design and Heat Dissipation Optimization for a 480 kW Charging Pile

Abstract As electric vehicle battery capacity and charging rates increase, the heat dissipation challenges of charging piles have intensified. In addition to adjusting the parameters of the device itself and cooling equipment, optimizing the air duct structure offers an effective means of thermal management, especially for the charging module located inside the air duct. To characterize the effectiveness of air duct optimization, a heat-flow coupling model is established for a 480 kW charging pile, and the maximum relative error of this model is 3.5%. With three types of objectives considered: temperature, air resistance, and consumables, a finite element simulation method is adapted, calculating 150 sets of raw data, and a proxy model is trained through multi-layer perceptron. SHERPA, NSGA-III, and PSO algorithms are used to obtain different optimal designs, respectively. The comparison between these designs indicate that the optimal design is fan down=171.4 mm, behand move=5.3 mm, and front move=33.4 mm. Compared with the original design, the total air intake volume increases by 10.28%, the maximum decrease in air resistance is 36.9%, and the maximum decrease in the average temperature rise of the module is 13.57%.