As electric vehicle infrastructure continues to expand worldwide, reliable thermal management inside EV charging systems has become increasingly important. Charging stations operate in demanding outdoor environments where high temperatures, dust, humidity, and water exposure can significantly affect electronic components.
To address these challenges, an EV charger manufacturer in India partnered with EISKUHL to develop a customized cooling solution using the DC6010 frameless fan. The project required a compact, high-performance fan capable of delivering stable airflow while maintaining excellent waterproof performance for outdoor operation.
Client Location: India
Application: EV charger cooling system
Fan Model: DC6010 Frameless Fan
Mass Production Start: August 2024
Since the product entered mass production, it has delivered stable performance and reliable operation in real-world charging infrastructure.
The Indian customer specializes in manufacturing EV charging equipment for both public and commercial charging networks. Their charging units integrate high-power electronic components, including power modules, control boards, and communication systems. These components generate significant heat during operation and require efficient cooling to maintain safe temperatures.
However, the installation environment created several technical challenges.
EV chargers are typically installed outdoors or in semi-outdoor environments where they are exposed to rain, humidity, and dust. Traditional cooling fans often struggle to maintain reliability when exposed to moisture.
The customer required a cooling solution capable of operating reliably even when exposed to water spray or dripping water.
In addition to environmental protection, the fan needed to meet precise performance specifications. The cooling system design required the fan to achieve specific targets for:
Rotational speed (RPM)
Airflow performance
Stable operating characteristics
Any compromise in airflow or speed would reduce cooling efficiency and potentially affect the performance of the charger.
Many fans can achieve high IP ratings, but often at the cost of reduced airflow or increased power consumption. The customer emphasized that waterproofing must not degrade:
Operating performance
Airflow efficiency
Product lifespan
In other words, the fan needed to deliver both high protection and high performance simultaneously.Customer Case Study: DC6010 Frameless Fan for EV Charger Cooling in India
To meet these requirements, EISKUHL recommended the DC6010 frameless fan, a compact cooling solution designed for high-efficiency airflow and flexible system integration.
The frameless structure allows the fan motor and impeller to be directly integrated into the EV charger’s internal airflow structure. This design offers several advantages:
Optimized airflow paths within the charger enclosure
Reduced overall system size
Improved cooling efficiency for power modules
Because the fan is not constrained by a traditional frame, engineers can integrate it more precisely within the thermal management layout.
One of the key requirements was achieving IP65 waterproof capability. The engineering team optimized several aspects of the fan design to ensure reliable operation in environments exposed to water spray or dripping water.
These improvements included:
Enhanced sealing structure for the motor assembly
Protective coating on electronic components
Waterproof design for internal circuits
With these measures, the fan can maintain stable operation even when exposed to moisture, ensuring that outdoor EV chargers remain reliable during rain or high humidity conditions.
Despite the added environmental protection, the fan was engineered to maintain the required operating specifications.
The DC6010 frameless fan delivers:
Stable rotational speed (RPM)
Reliable airflow performance
High efficiency cooling capability
Extensive validation testing ensured that waterproofing measures did not negatively impact the fan’s thermal performance or operational stability.
EV charging infrastructure is expected to operate continuously for many years. Therefore, the fan design also focused on durability and lifespan.
By optimizing motor efficiency and structural reliability, the solution ensures consistent performance over extended operating cycles.
After completing engineering verification and customer validation, the DC6010 frameless fan successfully passed all performance and environmental tests.
Mass production officially began in August 2024.
Since then, the manufacturing and delivery process has remained stable. EISKUHL maintains strict quality control procedures to ensure every production batch meets the same technical standards validated during development.
Monthly deliveries are shipped according to the customer’s production schedule, ensuring uninterrupted supply for EV charger manufacturing.
Since entering mass production, the DC6010 frameless fan has demonstrated strong performance in real-world applications.
The product has now been in stable mass production for approximately 19 months. During this period, the fan has consistently met the customer’s expectations in terms of performance and reliability.
Key outcomes include:
Stable airflow performance in operating EV chargers
Reliable waterproof protection in outdoor environments
Consistent product quality across production batches
The customer has reported an excellent overall experience with the solution. Product reliability, consistent supply, and stable cooling performance have helped support their EV charger production and deployment.
The strong performance of the chargers equipped with the DC6010 frameless fan has also translated into positive market reception.
As demand for EV charging infrastructure continues to increase, the customer’s order volume has grown steadily. This growth has led to a continuous increase in fan orders as well.
