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Keywords = battery-only operation

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42 pages, 5483 KiB  
Article
Optimal Sizing of Battery Energy Storage System for Implicit Flexibility in Multi-Energy Microgrids
by Andrea Scrocca, Maurizio Delfanti and Filippo Bovera
Appl. Sci. 2025, 15(15), 8529; https://doi.org/10.3390/app15158529 (registering DOI) - 31 Jul 2025
Abstract
In the context of urban decarbonization, multi-energy microgrids (MEMGs) are gaining increasing relevance due to their ability to enhance synergies across multiple energy vectors. This study presents a block-based MILP framework developed to optimize the operations of a real MEMG, with a particular [...] Read more.
In the context of urban decarbonization, multi-energy microgrids (MEMGs) are gaining increasing relevance due to their ability to enhance synergies across multiple energy vectors. This study presents a block-based MILP framework developed to optimize the operations of a real MEMG, with a particular focus on accurately modeling the structure of electricity and natural gas bills. The objective is to assess the added economic value of integrating a battery energy storage system (BESS) under the assumption it is employed to provide implicit flexibility—namely, bill management, energy arbitrage, and peak shaving. Results show that under assumed market conditions, tariff schemes, and BESS costs, none of the analyzed BESS configurations achieve a positive net present value. However, a 2 MW/4 MWh BESS yields a 3.8% reduction in annual operating costs compared to the base case without storage, driven by increased self-consumption (+2.8%), reduced thermal energy waste (–6.4%), and a substantial decrease in power-based electricity charges (–77.9%). The performed sensitivity analyses indicate that even with a significantly higher day-ahead market price spread, the BESS is not sufficiently incentivized to perform pure energy arbitrage and that the effectiveness of a time-of-use power-based tariff depends not only on the level of price differentiation but also on the BESS size. Overall, this study provides insights into the role of BESS in MEMGs and highlights the need for electricity bill designs that better reward the provision of implicit flexibility by storage systems. Full article
(This article belongs to the Special Issue Innovative Approaches to Optimize Future Multi-Energy Systems)
22 pages, 16421 KiB  
Article
Deep Neural Network with Anomaly Detection for Single-Cycle Battery Lifetime Prediction
by Junghwan Lee, Longda Wang, Hoseok Jung, Bukyu Lim, Dael Kim, Jiaxin Liu and Jong Lim
Batteries 2025, 11(8), 288; https://doi.org/10.3390/batteries11080288 - 30 Jul 2025
Abstract
Large-scale battery datasets often contain anomalous data due to sensor noise, communication errors, and operational inconsistencies, which degrade the accuracy of data-driven prognostics. However, many existing studies overlook the impact of such anomalies or apply filtering heuristically without rigorous benchmarking, which can potentially [...] Read more.
Large-scale battery datasets often contain anomalous data due to sensor noise, communication errors, and operational inconsistencies, which degrade the accuracy of data-driven prognostics. However, many existing studies overlook the impact of such anomalies or apply filtering heuristically without rigorous benchmarking, which can potentially introduce biases into training and evaluation pipelines. This study presents a deep learning framework that integrates autoencoder-based anomaly detection with a residual neural network (ResNet) to achieve state-of-the-art prediction of remaining useful life at the cycle level using only a single-cycle input. The framework systematically filters out anomalous samples using multiple variants of convolutional and sequence-to-sequence autoencoders, thereby enhancing data integrity before optimizing and training the ResNet-based models. Benchmarking against existing deep learning approaches demonstrates a significant performance improvement, with the best model achieving a mean absolute percentage error of 2.85% and a root mean square error of 40.87 cycles, surpassing prior studies. These results indicate that autoencoder-based anomaly filtering significantly enhances prediction accuracy, reinforcing the importance of systematic anomaly detection in battery prognostics. The proposed method provides a scalable and interpretable solution for intelligent battery management in electric vehicles and energy storage systems. Full article
(This article belongs to the Special Issue Machine Learning for Advanced Battery Systems)
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38 pages, 2182 KiB  
Article
Smart Grid Strategies for Tackling the Duck Curve: A Qualitative Assessment of Digitalization, Battery Energy Storage, and Managed Rebound Effects Benefits
by Joseph Nyangon
Energies 2025, 18(15), 3988; https://doi.org/10.3390/en18153988 - 25 Jul 2025
Viewed by 324
Abstract
Modern utilities face unprecedented pressures as trends in digital transformation and democratized energy choice empower consumers to engage in peak shaving, flexible load management, and adopt grid automation and intelligence solutions. A powerful confluence of architectural, technological, and socio-economic forces is transforming the [...] Read more.
Modern utilities face unprecedented pressures as trends in digital transformation and democratized energy choice empower consumers to engage in peak shaving, flexible load management, and adopt grid automation and intelligence solutions. A powerful confluence of architectural, technological, and socio-economic forces is transforming the U.S. electricity market, triggering significant changes in electricity production, transmission, and consumption. Utilities are embracing digital twins and repurposed Utility 2.0 concepts—distributed energy resources, microgrids, innovative electricity market designs, real-time automated monitoring, smart meters, machine learning, artificial intelligence, and advanced data and predictive analytics—to foster operational flexibility and market efficiency. This analysis qualitatively evaluates how digitalization, Battery Energy Storage Systems (BESSs), and adaptive strategies to mitigate rebound effects collectively advance smart duck curve management. By leveraging digital platforms for real-time monitoring and predictive analytics, utilities can optimize energy flows and make data-driven decisions. BESS technologies capture surplus renewable energy during off-peak periods and discharge it when demand spikes, thereby smoothing grid fluctuations. This review explores the benefits of targeted digital transformation, BESSs, and managed rebound effects in mitigating the duck curve problem, ensuring that energy efficiency gains translate into actual savings. Furthermore, this integrated approach not only reduces energy wastage and lowers operational costs but also enhances grid resilience, establishing a robust framework for sustainable energy management in an evolving market landscape. Full article
(This article belongs to the Special Issue Policy and Economic Analysis of Energy Systems)
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21 pages, 3984 KiB  
Article
Organic Acid Leaching of Black Mass with an LFP and NMC Mixed Chemistry
by Marc Simon Henderson, Chau Chun Beh, Elsayed Oraby and Jacques Eksteen
Recycling 2025, 10(4), 145; https://doi.org/10.3390/recycling10040145 - 21 Jul 2025
Viewed by 342
Abstract
There is an increasing demand for the development of efficient and sustainable battery recycling processes. Currently, many recycling processes rely on toxic inorganic acids to recover materials from high-value battery chemistries such as lithium nickel manganese cobalt oxides (NMCs) and lithium cobalt oxide [...] Read more.
There is an increasing demand for the development of efficient and sustainable battery recycling processes. Currently, many recycling processes rely on toxic inorganic acids to recover materials from high-value battery chemistries such as lithium nickel manganese cobalt oxides (NMCs) and lithium cobalt oxide (LCOs). However, as cell manufacturers seek more cost-effective battery chemistries, the value of the spent battery value chain is increasingly diluted by chemistries such as lithium iron phosphate (LFPs). These cheaper alternatives present a difficulty when recycling, as current recycling processes are geared towards dealing with high-value chemistries; thus, the current processes become less economical. To date, much research is focused on treating a single battery chemistry; however, often, the feed material entering a battery recycling facility is contaminated with other battery chemistries, e.g., LFP feed contaminated with NMC, LCO, or LMOs. This research aims to selectively leach various battery chemistries out of a mixed feed material with the aid of a green organic acid, namely oxalic acid. When operating at the optimal conditions (2% solids, 0.25 M oxalic acid, natural pH around 1.15, 25 °C, 60 min), this research has proven that oxalic acid can be used to selectively dissolve 95.58% and 93.57% of Li and P, respectively, from a mixed LFP-NMC mixed feed, all while only extracting 12.83% of Fe and 8.43% of Mn, with no Co and Ni being detected in solution. Along with the high degree of selectivity, this research has also demonstrated, through varying the pH, that the selectivity of the leaching system can be altered. It was determined that at pH 0.5 the system dissolved both the NMC and LFP chemistries; at a pH of 1.15, the LFP chemistry (Li and P) was selectively targeted. Finally, at a pH of 4, the NMC chemistry (Ni, Co and Mn) was selectively dissolved. Full article
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21 pages, 2547 KiB  
Article
Remaining Available Energy Prediction for Energy Storage Batteries Based on Interpretable Generalized Additive Neural Network
by Ji Qi, Pengrui Li, Yifan Dong, Zhicheng Fu, Zhanguo Wang, Yong Yi and Jie Tian
Batteries 2025, 11(7), 276; https://doi.org/10.3390/batteries11070276 - 20 Jul 2025
Viewed by 212
Abstract
Precise estimation of the remaining available energy in batteries is not only key to improving energy management efficiency, but also serves as a critical safeguard for ensuring the safe operation of battery systems. To address the challenges associated with energy state estimation under [...] Read more.
Precise estimation of the remaining available energy in batteries is not only key to improving energy management efficiency, but also serves as a critical safeguard for ensuring the safe operation of battery systems. To address the challenges associated with energy state estimation under dynamic operating conditions, this study proposes a method for predicting the remaining available energy of energy storage batteries based on an interpretable generalized additive neural network (IGANN). First, considering the variability in battery operating conditions, the study designs a battery working voltage threshold that accounts for safety margins and proposes an available energy state assessment metric, which enhances prediction consistency under different discharge conditions. Subsequently, 12 features are selected from both direct observation and statistical characteristics to capture the operating condition information of the battery, and a dataset is constructed using actual operational data from an energy storage station. Finally, the model is trained and validated on the feature dataset. The validation results show that the model achieves an average absolute error of 2.39%, indicating that it effectively captures the energy variation characteristics within the 0.2 C to 0.6 C dynamic current range. Furthermore, the contribution of each feature is analyzed based on the model’s interpretability, and the model is optimized by utilizing high-contribution features. This optimization improves both the accuracy and runtime efficiency of the model. Finally, a dynamic prediction is conducted for a discharge cycle, comparing the predictions of the IGANN model with those of three other machine learning methods. The IGANN model demonstrates the best performance, with the average absolute error consistently controlled within 3%, proving the model’s accuracy and robustness under complex conditions. Full article
(This article belongs to the Special Issue Advances in Lithium-Ion Battery Safety and Fire: 2nd Edition)
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20 pages, 437 KiB  
Article
Post-Quantum Key Exchange and Subscriber Identity Encryption in 5G Using ML-KEM (Kyber)
by Qaiser Khan, Sourav Purification and Sang-Yoon Chang
Information 2025, 16(7), 617; https://doi.org/10.3390/info16070617 - 19 Jul 2025
Viewed by 233
Abstract
5G addresses user privacy concerns in cellular networking by encrypting a subscriber identifier with elliptic-curve-based encryption and then transmitting it as ciphertext known as a Subscriber Concealed Identifier (SUCI). However, an adversary equipped with a quantum computer can break a discrete-logarithm-based elliptic curve [...] Read more.
5G addresses user privacy concerns in cellular networking by encrypting a subscriber identifier with elliptic-curve-based encryption and then transmitting it as ciphertext known as a Subscriber Concealed Identifier (SUCI). However, an adversary equipped with a quantum computer can break a discrete-logarithm-based elliptic curve algorithm. Consequently, the user privacy in 5G is at stake against quantum attacks. In this paper, we study the incorporation of the post-quantum ciphers in the SUCI calculation both at the user equipment and at the core network, which involves the shared-key exchange and then using the resulting key for the ID encryption. We experiment on different hardware platforms to analyze the PQC key exchange and encryption using NIST-standardized CRYSTALS-Kyber (which is now called an ML-KEM after the standardization selection by NIST). Our analyses focus on the performances and compare the Kyber-based key exchange and encryption with the current (pre-quantum) elliptic curve Diffie–Hellman (ECDH). The performance analyses are critical because mobile networking involves resource-limited and battery-operating mobile devices. We measure and analyze not only the time and CPU-processing performances but also the energy and power performances. Our analyses show that Kyber-512 is the most efficient and even has better performance (i.e., faster computations and lower energy consumption) than ECDH. Full article
(This article belongs to the Special Issue Public Key Cryptography and Privacy Protection)
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19 pages, 2017 KiB  
Article
Analysis of Grid Scale Storage Effectiveness for a West African Interconnected Transmission System
by Julius Abayateye and Daniel Zimmerle
Energies 2025, 18(14), 3741; https://doi.org/10.3390/en18143741 - 15 Jul 2025
Viewed by 227
Abstract
The West Africa Power Pool (WAPP) Interconnected Transmission System (WAPPITS) has faced challenges with frequency control due to limited primary frequency control reserves (PFRs). Battery Energy Storage Systems (BESSs) have been identified as a possible solution to address frequency control challenges and to [...] Read more.
The West Africa Power Pool (WAPP) Interconnected Transmission System (WAPPITS) has faced challenges with frequency control due to limited primary frequency control reserves (PFRs). Battery Energy Storage Systems (BESSs) have been identified as a possible solution to address frequency control challenges and to support growing levels of variable renewable energy in the WAPPITS. This paper uses a dynamic PSS/E grid simulation to evaluate the effectiveness of BESSs and conventional power plants for the maximum N-1 contingency scenario in WAPPITS—the loss of 400 MW of generation. BESSs outperform conventional power plants in fast frequency response; a BESS-only PFR mix produces the best technical performance for the metrics analyzed. However, this approach does not have the best marginal cost; a balanced mix of BESSs and conventional reserves achieves adequate performance on all metrics to meet grid requirements. This hybrid approach combines BESSs’ rapid power injection with the lower cost of conventional units, resulting in improved nadir frequencies (e.g., 49.70–49.76 Hz), faster settling times (1.00–2.20 s), and cost efficiency. The study indicates that an optimal approach to frequency control should include a combination of regulatory reforms and coordinated reserve procurement that includes BESS assets. Regulatory reforms should require or incentivize conventional plant to provide PFRs, possibly through creation of a (new to WAPPITS) market for ancillary services. While not a comprehensive analysis of all variables, these findings provide critical insights for policymakers and system operators. Full article
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27 pages, 7623 KiB  
Article
A Ladder-Type Carbon Trading-Based Low-Carbon Economic Dispatch Model for Integrated Energy Systems with Flexible Load and Hybrid Energy Storage Optimization
by Liping Huang, Fanxin Zhong, Chun Sing Lai, Bang Zhong, Qijun Xiao and Weitai Hsu
Energies 2025, 18(14), 3679; https://doi.org/10.3390/en18143679 - 11 Jul 2025
Viewed by 265
Abstract
This paper proposes a ladder carbon trading-based low-carbon economic dispatch model for integrated energy systems (IESs), incorporating flexible load optimization and hybrid energy storage systems consisting of battery and thermal energy storage. First, a ladder-type carbon trading mechanism is introduced, in which the [...] Read more.
This paper proposes a ladder carbon trading-based low-carbon economic dispatch model for integrated energy systems (IESs), incorporating flexible load optimization and hybrid energy storage systems consisting of battery and thermal energy storage. First, a ladder-type carbon trading mechanism is introduced, in which the carbon trading cost increases progressively with emission levels, thereby providing stronger incentives for emission reduction. Second, flexible loads are categorized and modeled as shiftable, transferable, and reducible types, each with distinct operational constraints and compensation mechanisms. Third, both battery and thermal energy storage systems are considered to improve system flexibility by storing excess energy and supplying it when needed. Finally, a unified optimization framework is developed to coordinate the dispatch of renewable generation, gas turbines, waste heat recovery units, and multi-energy storage devices while integrating flexible load flexibility. The objective is to minimize the total system cost, which includes energy procurement, carbon trading expenditures, and demand response compensation. Three comparative case studies are conducted to evaluate system performance under different operational configurations: the proposed comprehensive model, a carbon trading-only approach, and a conventional baseline scenario. Results demonstrate that the proposed framework effectively balances economic and environmental objectives through coordinated demand-side management, hybrid storage utilization, and the ladder-type carbon trading market mechanism. It reshapes the system load profile via peak shaving and valley filling, improves renewable energy integration, and enhances overall system efficiency. Full article
(This article belongs to the Special Issue Hybrid Battery Energy Storage System)
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13 pages, 920 KiB  
Project Report
Analysis of Primary and Secondary Frequency Control Challenges in African Transmission System
by Julius Abayateye and Daniel J. Zimmerle
Energy Storage Appl. 2025, 2(3), 10; https://doi.org/10.3390/esa2030010 - 8 Jul 2025
Cited by 1 | Viewed by 296
Abstract
This study analyzed the frequency control challenges within the West Africa Power Pool Interconnected Transmission System (WAPPITS) as it plans to incorporate variable renewable energy (VRE) resources, such as wind and solar energy. Concerns center on the ability of WAPPITS primary frequency control [...] Read more.
This study analyzed the frequency control challenges within the West Africa Power Pool Interconnected Transmission System (WAPPITS) as it plans to incorporate variable renewable energy (VRE) resources, such as wind and solar energy. Concerns center on the ability of WAPPITS primary frequency control reserves to adapt to high VRE penetration given the synchronization and frequency control problems experienced by the three separate synchronous blocks of WAPPITS. Optimizing solutions requires a better understanding of WAPPITS’ current frequency control approach. This study used questionnaires to understand operators’ practical experience with frequency control and compared these observations to field tests at power plants and frequency response metrics during system events. Eight (8) of ten (10) Transmission System Operators (TSOs) indicated that primary frequency control service was implemented in the TSO, but nine (9) of ten TSOs indicated that the reserves provided were inadequate to meet system needs. Five (5) of ten (10) respondents answered “yes” to the provision of secondary frequency control service, while only one (1) indicated that secondary reserves were adequate. Three (3) TSOs indicated they have AGC (Automatic Generation Control) installed in the control room, but none have implemented it for secondary frequency control. The results indicate a significant deficiency in primary control reserves, resulting in a reliance on under-frequency load shedding for primary frequency control. Additionally, the absence of an AGC system for secondary frequency regulation required manual intervention to restore frequency after events. To ensure the effectiveness of battery energy storage systems (BESSs) and the reliable operation of the WAPPITS with a higher penetration of inverter-based VRE, this paper recommends (a) implementing and enforcing basic primary frequency control structures through regional regulation and (b) establishing an ancillary services market to mobilize secondary frequency control resources. Full article
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18 pages, 4203 KiB  
Article
Enhancing Lithium-Ion Battery State-of-Health Estimation via an IPSO-SVR Model: Advancing Accuracy, Robustness, and Sustainable Battery Management
by Siyuan Shang, Yonghong Xu, Hongguang Zhang, Hao Zheng, Fubin Yang, Yujie Zhang, Shuo Wang, Yinlian Yan and Jiabao Cheng
Sustainability 2025, 17(13), 6171; https://doi.org/10.3390/su17136171 - 4 Jul 2025
Viewed by 348
Abstract
Precise forecasting of lithium-ion battery health status is crucial for safe, efficient, and sustainable operation throughout the battery life cycle, especially in applications like electric vehicles (EVs) and renewable energy storage systems. In this study, an improved particle swarm optimization–support vector regression (IPSO-SVR) [...] Read more.
Precise forecasting of lithium-ion battery health status is crucial for safe, efficient, and sustainable operation throughout the battery life cycle, especially in applications like electric vehicles (EVs) and renewable energy storage systems. In this study, an improved particle swarm optimization–support vector regression (IPSO-SVR) model is proposed for dynamic hyper-parameter tuning, integrating multiple intelligent optimization algorithms (including PSO, genetic algorithm, whale optimization, and simulated annealing) to enhance the accuracy and generalization of battery state-of-health (SOH) estimation. The model dynamically adjusts SVR hyperparameters to better capture the nonlinear aging characteristics of batteries. We validate the approach using a publicly available NASA lithium-ion battery degradation dataset (cells B0005, B0006, B0007). Key health features are extracted from voltage–capacity curves (via incremental capacity analysis), and correlation analysis confirms their strong relationship with battery capacity. Experimental results show that the proposed IPSO-SVR model outperforms a conventional PSO-SVR benchmark across all three datasets, achieving higher prediction accuracy: a mean MAE of 0.611%, a mean RMSE of 0.794%, a mean MSE of 0.007%, and robustness a mean R2 of 0.933. These improvements in SOH prediction not only ensure more reliable battery management but also support sustainable energy practices by enabling longer battery life spans and more efficient resource utilization. Full article
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11 pages, 3956 KiB  
Proceeding Paper
Implementation of Bidirectional Converter with Asymmetrical Half-Bridge Converter Based on an SRM Drive Using PV for Electric Vehicles
by Ramabadran Ramaprabha, Ethirajan Anjana, Sureshkumar Hariprasath, Sulaimon Mohammed Ashik, Medarametala Venkata Sai Kiran and Tikarey Yoganand Navinsai Kaarthik
Eng. Proc. 2025, 93(1), 15; https://doi.org/10.3390/engproc2025093015 - 2 Jul 2025
Viewed by 197
Abstract
Due to the high demand for fuel efficiency, electric vehicles have come into the picture, as they only use batteries to power the vehicle. This requires constant charging of the batteries at charging stations, which are costly and impractical to install. But it [...] Read more.
Due to the high demand for fuel efficiency, electric vehicles have come into the picture, as they only use batteries to power the vehicle. This requires constant charging of the batteries at charging stations, which are costly and impractical to install. But it is possible to install charging stations by making use of photovoltaic (PV) cells and demagnetization currents to self-charge batteries under stand-still conditions. The design of a bidirectional converter with asymmetrical half-bridge converter based on a switched reluctance motor (SRM) drive, using PV for electric vehicles, is implemented in this paper. It consists of developing a control unit (GCU), Li-ion battery pack, and photovoltaic (PV) solar cells that are integrated with a bidirectional converter and asymmetrical half-bridge converter (AHBC) to provide power to the SRM drive. The solar-assisted SRM drive can be operated in either the motoring mode or charging mode. In the motoring-mode GCU, the battery or PV energy can be used in any combination to power the SRM. In the charging-mode PV, the GCU and AC grids are used to charge the battery under stand-still conditions. This work helps in the self-charging of batteries using either the GCU or PV cells, as well as aids in the improvement in the performance characteristics. Also, this work compares the performance metrics for the proposed system and conventional system. The performance of the drive system using PV cells/GCU is evaluated and verified through MatLab/Simulink and experimental results. Full article
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35 pages, 14682 KiB  
Article
Fast-Balancing Passive Battery Management System with Remote Monitoring for the Automotive Industry
by Ionuț-Constantin Guran, Adriana Florescu, Nicu Bizon and Lucian Andrei Perișoară
Electronics 2025, 14(13), 2606; https://doi.org/10.3390/electronics14132606 - 27 Jun 2025
Viewed by 310
Abstract
Batteries have become the main power source in today’s automotive systems. This paper proposes the design of a fast-balancing passive battery management system (BMS) with remote monitoring for the automotive domain. This system is designed for four series-connected lithium iron phosphate (LiFePO4) cells, [...] Read more.
Batteries have become the main power source in today’s automotive systems. This paper proposes the design of a fast-balancing passive battery management system (BMS) with remote monitoring for the automotive domain. This system is designed for four series-connected lithium iron phosphate (LiFePO4) cells, which are the preferred choice in the automotive industry. The results show that the proposed BMS can monitor the cell voltages with an error lower than 0.12%, and it can perform the balancing operation successfully with maximum currents of 750 mA during both charging and discharging cycles, not only for LiFePO4 cells, but also for lithium-ion (Li-ion) cells. Furthermore, the cell voltages are sent over the controller area network (CAN) interface for remote monitoring. Full article
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17 pages, 1865 KiB  
Article
Simulation of a Hybrid Propulsion System on Tugboats Operating in the Strait of Istanbul
by Mustafa Nuran, Murat Bayraktar and Onur Yuksel
Sustainability 2025, 17(13), 5834; https://doi.org/10.3390/su17135834 - 25 Jun 2025
Viewed by 465
Abstract
The implementation of hybrid propulsion systems in vessels has gained prominence due to their significant advantages in energy efficiency and their reduction in harmful emissions, particularly during low engine load operations. This study evaluates hybrid propulsion system applications in two different tugboats, focusing [...] Read more.
The implementation of hybrid propulsion systems in vessels has gained prominence due to their significant advantages in energy efficiency and their reduction in harmful emissions, particularly during low engine load operations. This study evaluates hybrid propulsion system applications in two different tugboats, focusing on fuel consumption and engine load across eight distinct operational scenarios, including Istanbul Strait crossings and towing and pushing manoeuvres. The scenarios incorporate asynchronous electric motors with varying power ratings, lead-acid and lithium iron phosphate batteries with distinct storage capacities, and photovoltaic panels of different sizes. The highest fuel savings of 72.4% were recorded in the second scenario, which involved only towing and pushing operations using lithium iron phosphate batteries. In contrast, the lowest fuel savings of 5.2% were observed in the sixth scenario, focused on a strait crossing operation employing lead-acid batteries. Although integrating larger-scale batteries into hybrid propulsion systems is vital for extended ship operations, their adoption is often limited by space and weight constraints, particularly on tugboats. Nevertheless, ongoing advancements in hybrid system technologies are expected to enable the integration of larger, more efficient systems, thereby enhancing fuel-saving potential. Full article
(This article belongs to the Section Energy Sustainability)
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28 pages, 1006 KiB  
Article
Next-Level Energy Management in Manufacturing: Facility-Level Energy Digital Twin Framework Based on Machine Learning and Automated Data Collection
by David Vance, Mingzhou Jin, Thomas Wenning, Sachin Nimbalkar and Christopher Price
Energies 2025, 18(13), 3242; https://doi.org/10.3390/en18133242 - 20 Jun 2025
Viewed by 337
Abstract
This research introduces an energy prediction framework at the facility level supported by automated data collection and machine learning models. It investigates whether reducing the prediction time scale allows for applying more complex machine learning techniques and if those techniques improve the prediction [...] Read more.
This research introduces an energy prediction framework at the facility level supported by automated data collection and machine learning models. It investigates whether reducing the prediction time scale allows for applying more complex machine learning techniques and if those techniques improve the prediction accuracy. The primary advantages of this framework lie in its automation of the energy prediction process and its provision of real-time energy data suitable for use in energy dashboards or digital twins. A sitewide dataset was created by combining 15 min energy and daily production data of five shops—assembly, battery, body (electric), body (gas), and paint—from a globally recognized electric vehicle manufacturer. Various machine learning models were evaluated on daily, weekly, and monthly datasets, including, in increasingly complex order: naïve, simple linear regression, net regularized generalized linear regression, principal component regression, k-nearest neighbor, random forest, and Bayesian regularized neural network. Compared to the current state-of-the-art energy consumption prediction for the industrial facility level, this research investigates more complex models and smaller time intervals for higher accuracy. The findings revealed that the more complex monthly models require a minimum of a year and a half of data to operate, while weekly models demand a year of data to achieve improved accuracy. Daily models can operate with only six months of data but exhibit poor performance due to reduced prediction accuracy of production. Key challenges identified include access to reliable, high-quality energy and production data and the initial demand for human labor. Full article
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28 pages, 9320 KiB  
Article
Embedded Sensor Data Fusion and TinyML for Real-Time Remaining Useful Life Estimation of UAV Li Polymer Batteries
by Jutarut Chaoraingern and Arjin Numsomran
Sensors 2025, 25(12), 3810; https://doi.org/10.3390/s25123810 - 18 Jun 2025
Viewed by 529
Abstract
The accurate real-time estimation of the remaining useful life (RUL) of lithium-polymer (LiPo) batteries is a critical enabler for ensuring the safety, reliability, and operational efficiency of unmanned aerial vehicles (UAVs). Nevertheless, achieving such prognostics on resource-constrained embedded platforms remains a considerable technical [...] Read more.
The accurate real-time estimation of the remaining useful life (RUL) of lithium-polymer (LiPo) batteries is a critical enabler for ensuring the safety, reliability, and operational efficiency of unmanned aerial vehicles (UAVs). Nevertheless, achieving such prognostics on resource-constrained embedded platforms remains a considerable technical challenge. This study proposes an end-to-end TinyML-based framework that integrates embedded sensor data fusion with an optimized feedforward neural network (FFNN) model for efficient RUL estimation under strict hardware limitations. The system collects voltage, discharge time, and capacity measurements through a lightweight data fusion pipeline and leverages the Edge Impulse platform with the EON™Compiler for model optimization. The trained model is deployed on a dual-core ARM Cortex-M0+ Raspberry Pi RP2040 microcontroller, communicating wirelessly with a LabVIEW-based visualization system for real-time monitoring. Experimental validation on an 80-gram UAV equipped with a 1100 mAh LiPo battery demonstrates a mean absolute error (MAE) of 3.46 cycles and a root mean squared error (RMSE) of 3.75 cycles. Model testing results show an overall accuracy of 98.82%, with a mean squared error (MSE) of 55.68, a mean absolute error (MAE) of 5.38, and a variance score of 0.99, indicating strong regression precision and robustness. Furthermore, the quantized (int8) version of the model achieves an inference latency of 2 ms, with memory utilization of only 1.2 KB RAM and 11 KB flash, confirming its suitability for real-time deployment on resource-constrained embedded devices. Overall, the proposed framework effectively demonstrates the feasibility of combining embedded sensor data fusion and TinyML to enable accurate, low-latency, and resource-efficient real-time RUL estimation for UAV battery health management. Full article
(This article belongs to the Section Intelligent Sensors)
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