Performance Analysis of Filter Resistance, Louver Airflow, and Fan Heat Dissipation to protect Swapping station Charger

Efficient thermal management in electric vehicle (EV) charging stations is critical for ensuring the reliability, safety, and longevity of power electronics. This study presents a comprehensive bench test analysis of three key parameters influencing charger cooling efficiency: filter resistance, louver airflow, and fan heat dissipation. A test bench was developed to measure pressure drop, temperature gradients, and air velocity variations across multiple filter types, louver orientations, and fan configurations. The results show that higher-efficiency filters (e.g., HEPA, MERV13) significantly reduce airflow, increasing thermal stress on electronic components, while optimized louver angles improve directional airflow, reduce turbulence, and enhance cooling performance. High-performance axial and centrifugal fans with adaptive control mechanisms further contribute to effective heat dissipation, maintaining stable operating temperatures under varying load conditions. This study provides data-driven recommendations for optimizing charger layout design by balancing filtration efficiency, airflow performance, and energy-efficient cooling—findings that are particularly valuable for fast-charging hubs, battery swapping stations, and high-power DC chargers