Key Takeaways:
- Exicom has commenced manufacturing liquid-cooled AC and DC power modules for EV chargers at its Hyderabad Smart Manufacturing Facility.
- This makes Exicom the first company in India to produce this advanced class of power electronics for global export.
- The modules are initially slated for Tritium’s DC charger portfolio in North America and Europe, with future integration into Exicom’s domestic offerings, including Harmony DC chargers.
- Liquid cooling addresses thermal stress, a major cause of power electronics failures (estimated at 60%), by maintaining internal temperatures approximately 10°C lower than air-cooled systems.
- The sealed, compact design promises enhanced reliability, continuous operation, and lower lifetime operating costs for EV charging infrastructure.
India’s Leap in EV Charging Technology
Hyderabad, India — In a significant development set to bolster the global electric vehicle (EV) charging infrastructure, Exicom, a leading player in EV charging solutions, has announced the commencement of manufacturing liquid-cooled AC and DC power modules. These advanced modules, produced at the company’s Smart Manufacturing Facility in Hyderabad, mark a pivotal moment, positioning Exicom as the first company in India to build this sophisticated class of power electronics for international markets.
This pioneering initiative underscores India’s growing capabilities in high-tech manufacturing and its potential to contribute substantially to the global EV ecosystem. The move is expected to have far-reaching implications for the reliability and efficiency of EV charging stations, both domestically and across key international territories.
Addressing the Achilles’ Heel of Fast Chargers: Thermal Management
The rapid expansion of electric vehicle adoption necessitates equally robust and reliable charging infrastructure. However, a persistent challenge in high-power fast chargers has been thermal management. Reliability studies indicate that thermal stress is responsible for nearly 60% of power electronics failures in charging systems.
Highlighting the critical nature of temperature control, Exicom emphasizes that a mere 10°C to 15°C rise in temperature can double a component’s failure rate. Traditional air-cooled systems often struggle to dissipate heat effectively, especially in demanding operational environments. Liquid coolant offers a superior solution, capable of holding internal temperatures approximately 10°C lower than their air-cooled counterparts, thereby significantly extending component life and overall charger reliability.
Anant Nahata, Exicom’s CEO and Managing Director, articulated the real-world impact of this challenge: “Anyone who has stood next to a fast charger on a 45-degree afternoon knows what heat does to electronics. EV Charging is getting faster with chargers running more hours a day, and customers expect them to work every season and at every site.” This observation underscores the urgent need for more resilient thermal management solutions in modern EV charging infrastructure.
Strategic Manufacturing Hub in Hyderabad
Exicom’s Hyderabad Smart Manufacturing Facility serves as the nerve center for this groundbreaking production. The facility is equipped with state-of-the-art automation, ensuring precision and consistency in the manufacturing process. Furthermore, digital traceability systems are integrated to monitor every stage of production, enhancing quality control and accountability. Specialized testing protocols are also in place to ensure that each liquid-cooled power module meets rigorous global standards before deployment.
The strategic choice of Hyderabad as a manufacturing hub reflects India’s ambition to become a global leader in advanced manufacturing, particularly in the burgeoning EV sector. This local production capacity not only supports India’s ‘Make in India’ initiative but also positions Exicom to serve diverse markets efficiently.
Unpacking the Liquid-Cooled Advantage
The newly produced liquid-cooled EV charger modules are a direct outcome of Exicom’s strategic acquisition of the DC fast charging company Tritium in 2024. These modules build on Tritium’s established in-house liquid-cooled capability, a technology that has been refined and proven across some of the world’s most challenging charging environments.
This integration of proven expertise with localized manufacturing empowers Exicom to deliver highly robust and efficient charging solutions. The design philosophy behind these modules prioritizes longevity and performance under strenuous conditions, critical factors for the widespread adoption and sustained operation of EV charging networks.
Enhancing Reliability and Operational Efficiency
The benefits of these liquid-cooled EV charger modules extend beyond mere temperature control. Exicom highlights several key advantages of their fully sealed construction. This design inherently prevents the ingress of dust, moisture, and corrosive salt air – common environmental factors that significantly shorten charger life in the field. This protection is vital for chargers deployed in various climates and geographical locations, ensuring consistent performance and reduced maintenance requirements.
Moreover, the advanced design facilitates more power delivery within a remarkably compact footprint. This efficiency in space utilization is crucial for urban installations where real estate is at a premium. The modules also promise continuous operation under heavy load, ensuring that fast chargers can consistently deliver peak performance even during high-demand periods. Ultimately, these innovations translate into lower operating costs over the module’s lifetime, offering a compelling economic advantage for charge point operators and fleet managers.
Global Reach and Local Impact
The initial batches of these liquid-cooled EV charger modules are primarily destined for markets in North America and Europe. They will be integrated into Tritium’s comprehensive DC charger portfolio, including the TRI-FLEX and DC-FLEX models, enhancing their performance and durability in these mature EV markets.
In subsequent phases, Exicom plans to introduce this cutting-edge technology closer to its own customer base in India. This includes charge point operators, electric vehicle fleets, and original equipment manufacturers (OEMs). The integration will occur through Tritium’s range of DC fast chargers, which are already being deployed across India. Furthermore, Exicom intends to design the liquid-cooled architecture into its own flagship Harmony DC chargers, ensuring that Indian consumers and businesses benefit directly from this advanced technology.
Anant Nahata emphasized the strategic importance of this localization: “Globally, liquid cooling has become the architecture of choice for high-power charging. We are bringing this technology to India. Local manufacturing matters because we now own more of that technology ourselves. We can engineer it, improve it and adapt it faster, for our customers here and across the world.” This statement underscores the dual objective of meeting global demand while simultaneously strengthening India’s domestic EV infrastructure capabilities through indigenous technological advancements.
Exicom’s Vision for a Robust EV Ecosystem
Exicom’s commitment to manufacturing liquid-cooled EV charger modules in India represents a significant step towards creating a more reliable, efficient, and sustainable EV charging ecosystem. By addressing the critical challenge of thermal management with an advanced, locally produced solution, the company is not only enhancing the performance of individual chargers but also contributing to the overall confidence in electric vehicle technology.
This strategic move solidifies Exicom’s position as an innovator and leader in the global EV charging landscape. The ability to engineer, improve, and adapt this technology locally ensures that both Indian and international markets will benefit from increasingly robust and future-proof charging solutions, driving the continued expansion and adoption of electric mobility worldwide.
Frequently Asked Questions (FAQ)
What is Exicom’s recent manufacturing announcement?
Exicom has begun manufacturing liquid-cooled AC and DC power modules for EV chargers at its Hyderabad Smart Manufacturing Facility. This makes them the first company in India to produce this class of power electronics specifically for global markets, signifying a major leap in domestic EV technology contributions.
Why is liquid cooling important for EV chargers?
Liquid cooling is crucial for high-power EV chargers because it effectively manages thermal stress, which causes approximately 60% of power electronics failures. It can maintain internal temperatures about 10°C lower than air-cooled systems, significantly extending component lifespan and enhancing charger reliability, especially in challenging climates.
Where will these liquid-cooled modules be initially deployed?
The first liquid-cooled modules from Exicom are primarily destined for North America and Europe. They will be integrated into Tritium’s DC charger portfolio, specifically models like TRI-FLEX and DC-FLEX, catering to international demand for high-performance and reliable EV charging solutions.
How will this technology benefit the Indian EV market?
While initially for global markets, later phases will bring this technology to Exicom’s Indian customers, including charge point operators and OEMs, through Tritium’s DC fast chargers. Exicom also plans to integrate this architecture into its Harmony DC chargers, enhancing the reliability and efficiency of India’s evolving EV infrastructure.
What are the key advantages of Exicom’s liquid-cooled modules?
Exicom’s liquid-cooled modules offer several benefits, including a fully sealed construction that protects against dust, moisture, and salt air. They also provide more power in a compact footprint, enable continuous operation under heavy load, and contribute to lower operating costs over the module’s lifetime, ensuring long-term efficiency.
What is the role of Exicom’s Hyderabad facility in this initiative?
The Hyderabad Smart Manufacturing Facility is central to this initiative, featuring automation, digital traceability, and specialized testing capabilities. This advanced setup ensures high-quality production of the liquid-cooled EV charger modules for both domestic and international distribution, bolstering India’s position in advanced manufacturing.
How does Exicom’s acquisition of Tritium relate to this development?
Exicom acquired the DC fast charging company Tritium in 2024. The new liquid-cooled modules build on Tritium’s established in-house liquid-cooled capability, leveraging proven technology refined in tough charging environments globally. This acquisition significantly enhances Exicom’s expertise and market position in advanced EV charging solutions.