Key Takeaways:
- Exicom has commenced manufacturing liquid-cooled AC and DC power modules at its Hyderabad facility, marking a significant milestone as the first Indian company to produce this advanced power electronics for global distribution.
- These modules are initially destined for North American and European markets, specifically for integration into Tritium’s TRI-FLEX and DC-FLEX DC charger portfolios.
- Liquid cooling technology is projected to enhance charger reliability by mitigating thermal stress, which Exicom estimates accounts for nearly 60% of power electronics failures.
- The innovation promises extended charger lifespan, continuous operation under demanding conditions, and reduced operating costs due to improved thermal management and sealed construction.
- The initiative underscores India’s growing role in advanced EV charging infrastructure manufacturing and Exicom’s commitment to technological self-reliance and global market leadership.
In a significant stride for India’s burgeoning electric vehicle (EV) sector and its global supply chain contributions, Exicom has announced the commencement of manufacturing liquid-cooled AC and DC power modules. This production is taking place at its advanced Smart Manufacturing Facility in Hyderabad, positioning Exicom as the inaugural Indian enterprise to develop this sophisticated class of power electronics for international markets.
The strategic move underscores a pivotal moment for the nation’s manufacturing prowess, particularly in high-technology components crucial for the accelerating global EV charging infrastructure. These innovative modules represent a leap forward in reliability and performance for fast-charging solutions.
Strategic Deployment in Global Markets
The initial batches of these advanced liquid-cooled power modules are primarily earmarked for distribution across North America and Europe. Here, they will be integrated into the direct current (DC) charger portfolios of Tritium, specifically enhancing their TRI-FLEX and DC-FLEX models.
This export-first approach highlights the global demand for robust and efficient EV charging components, with India now emerging as a key manufacturing hub. The collaboration leverages the strengths of both entities to deliver cutting-edge solutions to mature EV markets.
Subsequent phases of this ambitious rollout are designed to bring the sophisticated technology closer to Exicom’s own extensive network of customers within India. This includes charge point operators, fleet managers, and original equipment manufacturers (OEMs), who will benefit from the deployment of Tritium’s range of DC fast chargers, now enhanced with Exicom’s locally manufactured liquid-cooled modules.
Beyond external partnerships, Exicom also has concrete plans to incorporate this advanced liquid-cooled architecture directly into its proprietary Harmony DC chargers, signaling a comprehensive integration strategy across its product lines.
Addressing Thermal Stress: The Core of Reliability
A critical challenge in the operational longevity and reliability of power electronics, especially in high-power EV chargers, is thermal stress. Exicom’s analysis, drawing from extensive reliability studies, estimates that nearly 60% of power electronics failures can be attributed directly to thermal degradation.
This highlights a significant vulnerability in conventional air-cooled systems, where sustained high temperatures can drastically reduce component lifespan. The company emphasizes that a rise of just 10° C to 15° C in temperature can effectively double a component’s failure rate, illustrating the acute sensitivity of these systems to heat.
The adoption of liquid cooling technology offers a compelling solution to this pervasive issue. By circulating a specialized coolant, these systems are designed to maintain internal component temperatures approximately 10° C lower than what typical air-cooled systems can achieve. This sustained reduction in operating temperature is crucial for extending the operational life and ensuring the consistent performance of EV chargers, particularly under heavy load and challenging environmental conditions.
Anant Nahata, CEO and Managing Director of Exicom, articulated the pressing need for such innovation. “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,” he stated, underscoring the real-world operational demands that these new modules are engineered to meet.
Leveraging Acquired Expertise and Advanced Engineering
The development of these liquid-cooled modules builds upon the robust in-house liquid-cooled capabilities that Tritium had cultivated. Exicom’s strategic acquisition of the DC fast charging company in 2024 has clearly paid dividends, enabling the integration and further refinement of this critical technology.
Exicom asserts that this class of module has undergone rigorous refinement across some of the most challenging charging environments globally. This extensive real-world testing and iterative development have culminated in a product engineered for exceptional resilience and performance, ready to tackle diverse climatic and operational demands.
Beyond thermal management, the design philosophy behind these modules emphasizes enhanced durability and operational efficiency. The fully sealed construction is a key feature, meticulously engineered to repel external contaminants such as dust, moisture, and corrosive salt air. These environmental factors are notorious for significantly shortening charger life in the field, making the sealed design a crucial protective measure.
Furthermore, Exicom credits the innovative design with enabling a higher power output within a more compact physical footprint. This translates into more efficient use of space at charging stations and potentially easier installation. The modules are also designed for continuous operation under full load, guaranteeing uninterrupted service even during peak demand periods. Over their entire lifetime, these design choices are expected to result in significantly lower operating costs for charger operators.
The Hyderabad Facility: A Hub of Advanced Manufacturing
The Hyderabad plant stands as a testament to Exicom’s commitment to advanced manufacturing practices. The facility is equipped with state-of-the-art automation, ensuring precision and consistency in the production process. Digital traceability systems are integrated throughout, allowing for meticulous tracking of each component and module from raw material to finished product, enhancing quality control and accountability.
Specialized testing protocols are also a cornerstone of the Hyderabad operation, ensuring that every module meets stringent performance and reliability standards before deployment. This sophisticated manufacturing ecosystem is primed to produce these crucial liquid-cooled modules for both domestic Indian requirements and the demanding international markets.
Mr. Nahata further elaborated on the strategic importance of this domestic manufacturing capability. “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 affirmed. This statement highlights the long-term vision of technological self-reliance, innovation, and responsiveness to market needs, both locally and internationally.
The development and production of these advanced liquid-cooled power modules by Exicom represent a landmark achievement for India’s EV infrastructure manufacturing landscape. By addressing the critical challenge of thermal management and enhancing charger reliability, Exicom is not only strengthening its own market position but also significantly contributing to the resilience and efficiency of global EV charging networks.
This initiative solidifies India’s growing stature as a producer of high-quality, high-tech components for the electric mobility revolution, paving the way for more sustainable and dependable charging solutions worldwide.
FAQ Section
What are Exicom’s new liquid-cooled power modules designed for?
Exicom’s new liquid-cooled AC and DC power modules are designed for integration into EV chargers, aiming to enhance their reliability, efficiency, and longevity, particularly in high-power fast-charging applications. They mitigate thermal stress, a primary cause of power electronics failures.
Where are these liquid-cooled modules being manufactured?
These advanced power modules are being manufactured at Exicom’s Smart Manufacturing Facility located in Hyderabad, India. This facility incorporates automation, digital traceability, and specialized testing to ensure high quality and precision.
Which markets will primarily receive these initial modules?
The first production batches of Exicom’s liquid-cooled power modules are primarily destined for deployment in North American and European markets. They will be integrated into Tritium’s DC charger portfolios, including the TRI-FLEX and DC-FLEX models.
How does liquid cooling improve EV charger reliability?
Liquid cooling significantly improves reliability by keeping internal temperatures approximately 10° C lower than air-cooled systems. This reduction directly addresses thermal stress, which Exicom estimates causes nearly 60% of power electronics failures, thus extending the lifespan of charger components.
What is the significance of local manufacturing for Exicom?
Local manufacturing allows Exicom to own more of the core technology, enabling faster engineering, improvement, and adaptation of the modules for specific customer needs. This enhances technological self-reliance and responsiveness for both Indian and global markets.
What are the other benefits of the new module design?
Beyond improved thermal management, the fully sealed construction protects against dust, moisture, and salt air, prolonging charger life. The design also allows for more power in a compact footprint, continuous operation under load, and lower operating costs over the module’s lifetime.
When did Exicom acquire Tritium?
Exicom acquired the DC fast charging company Tritium in 2024. This acquisition has been instrumental in integrating and refining the liquid-cooled capability that forms the basis of Exicom’s new power modules.