Key Takeaways (TL;DR)
- Exicom has commenced manufacturing liquid-cooled AC and DC power modules at its Hyderabad Smart Manufacturing Facility, positioning itself as India’s first producer of this advanced power electronics class for global distribution.
- These cutting-edge modules are initially slated for deployment in North America and Europe, integrated into Tritium’s TRI-FLEX and DC-FLEX DC charger portfolios.
- The innovation addresses a critical industry challenge: thermal stress, which accounts for nearly 60% of power electronics failures. Liquid cooling is proven to maintain internal temperatures approximately 10°C lower than air-cooled systems, significantly enhancing reliability and operational longevity.
- This strategic move, following Exicom’s 2024 acquisition of Tritium’s DC fast charging business, enables local manufacturing of advanced technology, fostering faster engineering, improvement, and adaptation for both domestic and international customers.
- The fully sealed design of these modules protects against environmental contaminants like dust, moisture, and salt air, ensuring continuous operation under heavy loads and reducing lifetime operating costs for EV charging infrastructure.
Hyderabad, India – In a significant leap for India’s electric vehicle (EV) infrastructure landscape, Exicom, a prominent player in the power electronics sector, has initiated the production of state-of-the-art liquid-cooled AC and DC power modules for EV chargers. This landmark development at its Hyderabad Smart Manufacturing Facility marks Exicom as the first company in India to produce this advanced class of power electronics, destined for discerning global markets.
The introduction of these highly engineered modules signifies a pivotal advancement in EV charging technology. It underscores a growing domestic capability in manufacturing critical components for the rapidly expanding global electric mobility ecosystem, ensuring higher reliability and performance standards for public and private charging networks.
Revolutionizing EV Charging with Advanced Thermal Management
The core innovation behind Exicom’s new offering lies in its sophisticated thermal management system. The company’s liquid-cooled power modules are designed to address one of the most persistent challenges in high-power charging: heat. Thermal stress is a leading cause of failure in power electronics, with reliability studies indicating it contributes to nearly 60% of component malfunctions.
Exicom’s analysis highlights a critical correlation: every 10°C to 15°C increase in temperature can effectively double a component’s failure rate. Traditional air-cooled systems, while effective for certain applications, often struggle to dissipate heat efficiently in high-power, high-demand charging environments. Liquid coolant, in contrast, offers superior heat transfer capabilities, effectively holding internal temperatures approximately 10°C lower than its air-cooled counterparts.
Anant Nahata, CEO and Managing Director of Exicom, emphasized the real-world impact of this technological upgrade. “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,” Nahata stated.
This commitment to robust thermal management is crucial as EV charging becomes faster and chargers operate for more extended periods, demanding unwavering performance irrespective of ambient conditions. The ability to maintain stable operating temperatures directly translates into enhanced reliability, extended lifespan, and consistent performance of charging infrastructure.
Strategic Global and Domestic Deployment
The initial deployment strategy for these sophisticated liquid-cooled power modules focuses on international markets. The first batches of modules are primarily earmarked for North America and Europe, where they will be integrated into Tritium’s extensive DC charger portfolio, including the TRI-FLEX and DC-FLEX series. This strategic integration leverages Tritium’s global presence and established market channels.
Exicom’s acquisition of Tritium’s DC fast charging business in 2024 has been instrumental in this technological synergy. The modules build upon Tritium’s well-established in-house liquid-cooled capability, a technology that has undergone rigorous refinement across some of the world’s most demanding charging environments. This collaboration ensures that the modules benefit from proven designs and extensive field experience.
Following this initial international rollout, Exicom plans to introduce this advanced technology closer to its own customer base in India. This will involve incorporating the modules into Tritium’s range of DC fast chargers, which are already being deployed across India. Furthermore, Exicom intends to integrate this robust liquid-cooled architecture into its proprietary Harmony DC chargers, catering to a diverse clientele that includes charge point operators, fleet managers, and automotive OEMs within the domestic market.
Engineering for Durability and Efficiency in EV Infrastructure
Beyond superior thermal performance, the design of these liquid-cooled power modules incorporates several critical features that contribute to their overall durability and operational efficiency. The fully sealed construction is a significant advantage, effectively keeping out common environmental antagonists such as dust, moisture, and corrosive salt air. These elements are known culprits in accelerating charger degradation and shortening the lifespan of power electronics in various field conditions.
By preventing ingress of these contaminants, Exicom significantly enhances the longevity and reliability of the EV charging units. The company also attributes the design to delivering more power within a compact physical footprint, a crucial consideration for space-constrained installations. This efficiency in design supports continuous operation under heavy loads, a non-negotiable requirement for commercial fast-charging applications.
Moreover, the enhanced reliability and extended lifespan facilitated by liquid cooling are expected to result in lower operating costs over the module’s lifetime. Reduced maintenance requirements, fewer component replacements, and consistent uptime contribute to a more economical and sustainable charging infrastructure, benefiting operators and, by extension, EV users.
Made in India: A Hub for Global EV Technology
Exicom’s Hyderabad Smart Manufacturing Facility plays a central role in this ambitious undertaking. The plant is equipped with state-of-the-art automation, ensuring precision and consistency in manufacturing processes. Digital traceability systems are in place, providing comprehensive data on each module’s journey from production to deployment, which is vital for quality control and future enhancements.
Furthermore, the facility incorporates specialized testing capabilities to rigorously validate the performance and reliability of these advanced liquid-cooled power modules. This robust manufacturing ecosystem positions the Hyderabad plant as a critical hub for producing these modules for both domestic consumption and international exports, reinforcing India’s emerging role in the global EV supply chain.
Nahata underscored the strategic importance of local manufacturing for advanced EV charging components. “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,” he asserted. This localization not only fosters self-reliance but also enables quicker response times to market demands and accelerated technological evolution.
Boosting India’s Electric Mobility Future
As India pushes for accelerated EV adoption, the development of robust, reliable, and efficient charging infrastructure is paramount. Exicom’s investment in manufacturing advanced liquid-cooled power modules for EV chargers directly contributes to strengthening this backbone. It ensures that the charging network can support the next generation of electric vehicles, offering faster charging speeds and dependable service.
This initiative solidifies India’s position on the global stage as a developer and manufacturer of cutting-edge electric vehicle technology. By addressing critical issues like thermal management, Exicom is not only enhancing the user experience but also driving the long-term sustainability and viability of the EV ecosystem both at home and abroad.
Frequently Asked Questions (FAQs)
What is the primary benefit of liquid-cooled power modules for EV chargers?
The primary benefit is enhanced reliability and extended lifespan. Liquid cooling effectively dissipates heat, maintaining internal temperatures significantly lower than air-cooled systems. This reduces thermal stress, which is responsible for nearly 60% of power electronics failures, ensuring more consistent and durable operation, especially for high-power DC fast charging.
Why is Exicom manufacturing these modules in India?
Exicom is manufacturing these modules at its Hyderabad facility to leverage local capabilities and strategically position India as a hub for advanced EV technology. This local production allows Exicom to engineer, improve, and adapt the technology faster for both domestic and global customers, fostering technological self-reliance and boosting India’s role in the global EV supply chain.
Which markets will initially receive these liquid-cooled modules?
Initially, the liquid-cooled power modules are primarily destined for North America and Europe. They will be integrated into Tritium’s DC charger portfolio, specifically the TRI-FLEX and DC-FLEX models, as part of Exicom’s broader strategy following its acquisition of Tritium’s DC fast charging business.
How do liquid-cooled systems compare to air-cooled systems in terms of temperature management?
Liquid-cooled systems are significantly more efficient in temperature management. Exicom reports that liquid coolant can hold internal temperatures approximately 10°C lower than air-cooled systems. This substantial temperature difference is critical for preventing thermal stress, which directly impacts the failure rate and operational longevity of power electronics.
What makes the new modules durable in diverse environments?
The modules feature a fully sealed construction, which is key to their durability in diverse environments. This design effectively prevents the ingress of dust, moisture, and salt air. Such contaminants are major contributors to component degradation and premature failure in traditional air-cooled systems, especially in challenging outdoor or coastal charging locations.
Will these modules be available for Exicom’s customers in India?
Yes, following their initial international deployment, Exicom plans to integrate this advanced liquid-cooled technology into Tritium’s DC fast chargers for deployment in India. Furthermore, Exicom intends to design this architecture into its own Harmony DC chargers, making these highly reliable solutions available to charge point operators, fleets, and OEMs domestically.