Key Takeaways
- Exicom has commenced manufacturing of liquid-cooled AC and DC power modules at its Hyderabad Smart Manufacturing Facility, marking a significant first for India in this class of power electronics.
- These advanced modules are initially slated for North American and European markets, specifically for Tritium’s DC charger portfolio, including TRI-FLEX and DC-FLEX.
- The innovation directly addresses thermal stress, a leading cause of power electronics failures, by maintaining internal temperatures roughly 10°C lower than air-cooled systems.
- The fully sealed design of these liquid-cooled EV charger modules enhances durability, enables continuous high-power operation, and reduces long-term operating costs.
- Local manufacturing in India empowers Exicom to rapidly engineer, improve, and adapt this critical technology for both domestic and international customers.
Hyderabad, India – Exicom, a prominent player in the electric vehicle (EV) charging ecosystem, has announced the commencement of manufacturing liquid-cooled AC and DC power modules at its state-of-the-art Smart Manufacturing Facility in Hyderabad. This strategic move positions Exicom as the first company in India to produce this advanced class of power electronics, designed to cater to demanding global EV charging markets.
The introduction of these cutting-edge liquid-cooled EV charger modules is expected to significantly enhance the reliability and efficiency of high-power charging solutions, addressing a critical challenge within the rapidly expanding EV infrastructure worldwide.
Setting a New Standard in EV Charging Technology
The newly produced liquid-cooled EV charger modules represent a leap forward in power electronics design for the electric mobility sector. By integrating liquid cooling, Exicom aims to mitigate one of the most persistent issues affecting EV charger performance and longevity: thermal stress. This manufacturing milestone underscores India’s growing capabilities in advanced technology production.
These modules are not only a testament to Exicom’s engineering prowess but also reflect a strategic vision to contribute substantially to the global EV charging landscape, starting with the most challenging operational environments.
Addressing the Critical Challenge of Thermal Stress
Thermal management is paramount for the optimal functioning and durability of power electronics, especially in high-power applications like DC fast charging. Exicom highlights that reliability studies attribute nearly 60% of power electronics failures to thermal stress. A mere 10° C to 15° C rise in temperature can effectively double a component’s failure rate, severely impacting charger uptime and operational costs.
The adoption of liquid cooling technology offers a robust solution, capable of holding internal temperatures approximately 10° C lower compared to traditional air-cooled systems. This significant temperature reduction is crucial for maintaining performance and extending the operational lifespan of EV charging infrastructure components.
Anant Nahata, Exicom’s CEO and Managing Director, underscored the practical implications of this 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,” Nahata stated, emphasizing the real-world demand for more resilient charging solutions.
Strategic Global Reach and Domestic Impact
The initial deployment of these liquid-cooled EV charger modules is primarily targeted at North American and European markets. Here, they will be integrated into Tritium’s comprehensive DC charger portfolio, which includes popular models such as TRI-FLEX and DC-FLEX. This collaboration leverages Tritium’s established presence in these regions, a company Exicom acquired in 2024, thereby consolidating technological capabilities and market reach.
In subsequent phases, Exicom plans to extend this advanced technology closer to its diverse customer base in India. This includes charge point operators (CPOs), large-scale fleets, and original equipment manufacturers (OEMs), who will benefit from Tritium’s range of DC fast chargers being deployed across the nation. Furthermore, Exicom intends to incorporate this liquid-cooled architecture into its own Harmony DC chargers, further solidifying its product offering.
Unpacking the Benefits of Liquid Cooling Technology
Beyond thermal regulation, the fully sealed construction of these liquid-cooled EV charger modules offers multiple advantages critical for charger longevity and operational efficiency. This design effectively prevents ingress from dust, moisture, and corrosive salt air—environmental factors that commonly shorten charger life in diverse field conditions.
Exicom credits the design with delivering more power within a compact footprint, a vital consideration for space-constrained installations. It also ensures continuous operation under heavy load, preventing performance degradation or shutdowns during peak usage. Over the module’s lifetime, these design characteristics translate into significantly lower operating costs due to reduced maintenance requirements and enhanced reliability.
Exicom’s Hyderabad Facility: A Hub of Advanced Manufacturing
The Hyderabad Smart Manufacturing Facility, where these liquid-cooled EV charger modules are being produced, is equipped with advanced capabilities designed to ensure high-quality output and scalability. The plant features robust automation, enabling precise and consistent manufacturing processes. Digital traceability is integrated throughout the production cycle, offering unparalleled insight into every component and stage of assembly, which is crucial for quality control and future improvements.
Moreover, the facility incorporates specialized testing protocols to validate the performance and durability of each module under rigorous conditions. This comprehensive manufacturing setup is geared towards meeting both domestic demand and the stringent quality requirements of international markets.
India’s Growing Role in Global EV Innovation
The local manufacturing of such sophisticated liquid-cooled EV charger modules in India represents a significant step towards technological self-reliance and global competitiveness. By bringing this advanced technology to Indian soil, Exicom is not only enhancing its product portfolio but also contributing to the broader ‘Make in India’ initiative for critical EV components.
Anant Nahata articulated the strategic importance of this local production. “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,” Nahata affirmed, highlighting the agility and innovation potential unlocked by indigenous manufacturing.
The Future of EV Charging Infrastructure
The rollout of liquid-cooled EV charger modules by Exicom is poised to redefine expectations for EV charging infrastructure. As electric vehicle adoption continues its rapid acceleration, the demand for fast, reliable, and durable charging solutions will only intensify. This technology addresses foundational reliability concerns, paving the way for more robust and efficient charging networks capable of supporting the next generation of electric vehicles.
This initiative underscores Exicom’s commitment to advancing sustainable mobility and solidifies India’s position as a key innovator and manufacturer in the global electric vehicle ecosystem.
Frequently Asked Questions (FAQ)
What are liquid-cooled power modules for EV chargers?
Liquid-cooled power modules are advanced electronic components used in EV chargers that utilize a liquid coolant, rather than air, to dissipate heat. This method is highly effective in managing the high temperatures generated during fast charging, significantly enhancing the module’s efficiency, reliability, and lifespan, especially in high-power DC fast chargers.
Why is liquid cooling important for EV chargers?
Thermal stress is a major cause of failure in power electronics. Liquid cooling keeps internal module temperatures roughly 10°C lower than air-cooled systems, drastically reducing failure rates and improving reliability. This is crucial for high-power EV charging, which generates substantial heat, ensuring consistent performance and charger uptime.
Which markets will initially receive these liquid-cooled modules?
Initially, Exicom’s liquid-cooled power modules are primarily destined for North American and European markets. They will be integrated into Tritium’s DC charger portfolio, including models like TRI-FLEX and DC-FLEX, catering to a global demand for advanced EV charging infrastructure.
How does Exicom’s Hyderabad facility contribute to this innovation?
Exicom’s Hyderabad Smart Manufacturing Facility is equipped with automation, digital traceability, and specialized testing capabilities. This advanced infrastructure enables the precise and high-quality production of liquid-cooled EV charger modules for both domestic and international markets, ensuring adherence to stringent performance standards.
What are the benefits of local manufacturing for this technology in India?
Local manufacturing allows Exicom to have greater control over the technology, fostering faster engineering, improvement, and adaptation of the liquid-cooled EV charger modules. This capability is vital for customizing solutions for diverse customer needs in India and worldwide, while also contributing to India’s technological self-reliance in the EV sector.