Ultra Fast Charging Shunt NEV Cold Plate Cooling High Current Scenario Solution

The ultra-fast charging shunt is a high-current, high-precision shunt resistor designed specifically for ultra-fast charging (flash charging) scenarios in new energy vehicles. Its core function is to achieve accurate current monitoring, efficient heat dissipation, and battery safety protection under extreme charging currents ranging from 800A to 2000A.

It is essentially a low-resistance, high-precision four-terminal resistor (shunt):

• Current Sampling: Connected in series in the main fast-charging circuit. When high current passes through, a weak millivolt-level voltage signal is generated according to Ohm's Law (V=I×R).
• Real-Time Monitoring: The BMS (Battery Management System) collects this voltage signal and accurately calculates the real-time charging current.
• Safety Control: Based on the monitored data, the BMS dynamically adjusts the charging power to prevent overcurrent and overheating, protecting battery cells.

• Ultra-High Current Rating: Standard ratings include 800A / 1000A / 1500A, with a maximum of up to 2000A, suitable for 1000V+ high-voltage platforms.
• Ultra-Low Internal Resistance & Low Power Loss: Made of special alloys (such as manganin and Karma) with optimized structure, featuring extremely low internal resistance (typically around 50μΩ), achieving low heat generation and fast heat dissipation.
• High Precision & Stability: Accuracy up to ±0.5% or higher, with minimal resistance drift across the full temperature range (-40℃~125℃), ensuring precise current monitoring.
• High-Efficiency Heat Dissipation Structure: Mostly adopts integrated copper substrate or laminated heat dissipation design, combined with air/liquid cooling to quickly conduct heat generated by high current.
• High Reliability: Compliant with AEC-Q200 automotive qualification and IATF 16949 certification, featuring vibration resistance, corrosion resistance, and long service life.

• Battery Lifespan Protection: Avoids direct high-current impact on battery cells, suppresses current fluctuations, controls charging temperature within a safe range, and reduces battery aging.
• Guaranteed Ultra-Fast Charging Speed: Low-loss design does not compromise charging efficiency, supporting ultra-fast charging demands such as "400 km range from 5 minutes of charging".
• System Safety Barrier: Provides real-time overcurrent detection, serving as the first critical line of defense against thermal runaway and triggering system protection.
• Adaptation to Extreme Environments: Maintains stable accuracy and performance even at -40℃ extreme cold or high-temperature conditions.

• New Energy Vehicles (EV/PHEV): Current sampling for on-board OBC (On-Board Charger) and BMS.
• Ultra-Fast Charging Stations: 480kW, 800kW, 1500kW high-power liquid-cooled charging piles.
• Energy Storage Systems: High-current charge/discharge circuit monitoring for large-scale energy storage power stations.
• Special Vehicles: High-power equipment such as electric heavy trucks, construction machinery, and electric ships.