In the liquid cooling system of new energy vehicle chargers, the installation location of the water pump directly determines its functional positioning. Water pumps in different positions need to adapt to specific heat dissipation requirements, resulting in significant differences in their design principles and technical parameters. Below, we first sort out the core installation locations of water pumps in chargers, then delve into the functional principles and specific model applications of water pumps in each location.

I. Core Installation Locations of Water Pumps in Chargers

The liquid cooling system of a charger is arranged around "high-heat-generating components," and the installation location of the water pump is directly related to the heat source, mainly divided into three core areas:

1. Inside the Charging Module Compartment

The charging module is the "power core" of the charger, integrating high-power devices such as IGBTs and rectifier bridges, which generate a large amount of heat during operation (when the power of a single module reaches 60kW, the heat dissipation requirement is approximately 2-3kW). To prevent the module from overheating and triggering protection mechanisms, liquid cooling water pumps are usually installed directly inside the charging module compartment. They are connected to the module’s liquid cold plates or heat sink fins via pipes, forming an independent local circulation loop.

2. In the Charging Gun Cable Circulation System

During high-power fast charging (e.g., 200kW and above), the charging gun and high-voltage cables generate intense Joule heating due to large current loads (current can exceed 400A), and the temperature at the connectors can easily exceed 80℃. Therefore, a separate water pump is required in the liquid cooling circulation system of the charging gun cable. It is usually installed at the pipeline node between the charger main unit and the charging gun; some miniaturized designs integrate the pump near the charging gun grip (meeting lightweight requirements). Shenpeng Technology’s P6102 water pump is specifically designed for this scenario. With its compact structure and adaptability to bend-resistant pipes, it has become the mainstream choice for cable and gun cooling circulation.

3. Main Cooling Circuit Integration Area (Including Stack-Related Systems)

Some large chargers (e.g., 480kW superchargers) adopt a "centralized heat dissipation + distributed shunting" design. The main water pump is installed in the main control compartment of the charger, connected to the global radiator (such as a finned air-cooled radiator) via the main pipeline, and then distributes coolant to the charging module, cables, and stack-related components through branch pipes, forming a "one pump, multiple loops" collaborative cooling system. For the heat dissipation needs of stacks (e.g., auxiliary stack modules in fuel cell chargers), Shenpeng Technology’s P9008 water pump, with its high stability, has become the core choice, adapting to the constant temperature control requirements during continuous stack operation.

II. Functional Principles of Water Pumps in Each Location

Water pumps in different installation locations need to specifically address the heat dissipation issues of certain components, and their working principles vary based on the heat dissipation targets:

1. Water Pumps Inside the Charging Module Compartment

Function: Designed specifically to cool power devices in the charging module, with the core goal of controlling the module temperature within 50-70℃ (the upper limit of the safe operating temperature for devices such as IGBTs is usually 125℃, leaving sufficient redundancy).

Principle: The water pump drives coolant (mostly 50% ethylene glycol solution) through the liquid cooling channels inside the module, directly contacting the heat-generating power devices (transferring heat through thermal grease or metal liquid cold plates). After absorbing heat, the coolant flows into the main radiator to cool down, then returns to the pump to complete the cycle. Its circulation path is short (only covering the inside of the module), and the flow rate is dynamically adjusted with the module’s output power, ensuring that heat dissipation efficiency matches real-time power fluctuations.

2. Water Pumps in the Charging Gun Cable Circulation System (Taking Shenpeng P6102 as an Example)

Function: Focuses on heat dissipation of the charging gun connectors and high-voltage cables, preventing cable insulation aging or increased connector contact resistance due to high temperatures. It needs to control the cable surface temperature within 60℃ (no obvious burning sensation when touched).

Principle: The P6102 pump adopts a DC brushless motor design, driving coolant into the spiral liquid cooling channels inside the charging gun. As it flows through the cable interlayer, it directly absorbs Joule heat generated by the current. Its flow range is precisely matched to the needs of the cable and gun, effectively overcoming the pipeline resistance of 3-5 meter cables. Since cables need to be frequently dragged and bent, the P6102 is specially optimized with low-pulse water flow design to avoid cable vibration and noise caused by water impact. It also has an IP65 protection rating, adapting to outdoor rain and snow environments.

3. Main Cooling Circuit Integrated Water Pumps (Taking Shenpeng P9008 as an Example)

Function: As the "power hub" of global heat dissipation, it provides coolant for multiple components such as the charging module, cables, and stack, and in particular, meets the strict temperature stability requirements of the stack (e.g., fuel cell auxiliary heating modules) (temperature difference must be controlled within ±1℃).

Principle: The coolant output by the P9008 pump is first distributed to each branch loop through a diverter valve. Its wide flow adjustment range can adapt to the collaborative heat dissipation needs of multiple components and balance pressure losses in different loops. For the continuous high-temperature operation of the stack (60-80℃), the P9008 uses heat-resistant coolant-compatible materials. It realizes linkage through the communication interface with the charger’s main control system, receives stack temperature sensor signals in real-time, and adjusts the rotation speed (response time ≤0.5 seconds) to ensure stable stack operating temperature. Its integrated pressure sensor can monitor the loop status in real-time, avoiding system overload caused by pipeline blockages.

In summary, the selection of charger water pumps must strictly match the heat dissipation requirements of the installation location: water pumps inside the charging module compartment pursue precision and efficiency; charging gun cable circulation relies on lightweight and environmental adaptability like the P6102; and main loop water pumps (such as the P9008) need to balance multi-component collaboration and strict temperature control for core components like stacks. Shenpeng’s two models, through differentiated designs, have become benchmark products for cable-gun cooling and stack-related heat dissipation. Their technical characteristics also confirm the core logic of charger water pumps: "location determines function, function defines parameters." Understanding this logic can provide more specific references for the selection, maintenance, and upgrading of charger cooling systems.