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Keywords = cooling energy

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18 pages, 6388 KiB  
Article
Spatial–Temporal Hotspot Management of Photovoltaic Modules Based on Fiber Bragg Grating Sensor Arrays
by Haotian Ding, Rui Guo, Huan Xing, Yu Chen, Jiajun He, Junxian Luo, Maojie Chen, Ye Chen, Shaochun Tang and Fei Xu
Sensors 2025, 25(15), 4879; https://doi.org/10.3390/s25154879 (registering DOI) - 7 Aug 2025
Abstract
Against the backdrop of an urgent energy crisis, solar energy has attracted sufficient attention as one of the most inexhaustible and friendly types of environmental energy. Faced with long service and harsh environment, the poor performance ratios of photovoltaic arrays and safety hazards [...] Read more.
Against the backdrop of an urgent energy crisis, solar energy has attracted sufficient attention as one of the most inexhaustible and friendly types of environmental energy. Faced with long service and harsh environment, the poor performance ratios of photovoltaic arrays and safety hazards are frequently boosted worldwide. In particular, the hot spot effect plays a vital role in weakening the power generation performance and reduces the lifetime of photovoltaic (PV) modules. Here, our research reports a spatial–temporal hot spot management system integrated with fiber Bragg grating (FBG) temperature sensor arrays and cooling hydrogels. Through finite element simulations and indoor experiments in laboratory conditions, a superior cooling effect of hydrogels and photoelectric conversion efficiency improvement have been demonstrated. On this basis, field tests were carried out in which the FBG arrays detected the surface temperature of the PV module first, and then a classifier based on an optimized artificial neural network (ANN) recognized hot spots with an accuracy of 99.1%. The implementation of cooling hydrogels as a feedback mechanism achieved a 7.7 °C reduction in temperature, resulting in a 5.6% enhancement in power generation efficiency. The proposed strategy offers valuable insights for conducting predictive maintenance of PV power plants in the case of hot spots. Full article
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14 pages, 2771 KiB  
Article
Numerical Simulation and Experimental Study of Millisecond Percussion Drilling in Titanium Alloy
by Liang Wang, Long Xu, Changjian Wu, Yefei Rong and Kaibo Xia
Materials 2025, 18(15), 3719; https://doi.org/10.3390/ma18153719 (registering DOI) - 7 Aug 2025
Abstract
This study addresses the challenge of drilling film-cooling holes in the turbine blades of aircraft engines. Titanium alloy TC4 was selected as the experimental material. The laser-drilling process was simulated with ANSYS to determine optimal parameters, which were subsequently applied in machining trials. [...] Read more.
This study addresses the challenge of drilling film-cooling holes in the turbine blades of aircraft engines. Titanium alloy TC4 was selected as the experimental material. The laser-drilling process was simulated with ANSYS to determine optimal parameters, which were subsequently applied in machining trials. An impact-drilling method was then used to evaluate how pulse width, pulse energy, and pulse count affect micro-hole entrance and exit diameters, taper, and roundness. Simulations revealed that pulse energy and pulse count predominantly govern entrance and exit diameters, whereas pulse count and pulse width exert a stronger influence on taper. Experiments confirmed that entrance and exit diameters increased as pulse energy rose from 2.0 J to 2.8 J; taper increased as pulse width widened from 0.6 ms to 1.4 ms; and entrance diameter, exit diameter, and taper all grew as pulse count rose from 40 to 60. Pulse width and pulse count also significantly affected hole roundness. Full article
15 pages, 2189 KiB  
Article
Synthesis, Crystal Structures and Magnetic Properties of Lanthanide Complexes with Rhodamine Benzoyl Hydrazone Ligands
by Lin Miao, Dong-Mei Zhu, Cai-Ming Liu, Yi-Quan Zhang and Hui-Zhong Kou
Magnetochemistry 2025, 11(8), 68; https://doi.org/10.3390/magnetochemistry11080068 - 7 Aug 2025
Abstract
Given the outstanding magnetic characteristics of lanthanide ions, the development of mononuclear or multinuclear lanthanide complexes becomes imperative. Previous research showed that a series of mononuclear Dy(III) complexes of rhodamine benzoyl hydrazone Schiff base ligands exhibit remarkable single-molecule magnetic properties and fluorescence. In [...] Read more.
Given the outstanding magnetic characteristics of lanthanide ions, the development of mononuclear or multinuclear lanthanide complexes becomes imperative. Previous research showed that a series of mononuclear Dy(III) complexes of rhodamine benzoyl hydrazone Schiff base ligands exhibit remarkable single-molecule magnetic properties and fluorescence. In this study, we used analogous ligands to synthesize lanthanide complexes [Dy(HL1-o)(NO3)2(CH3OH)2]NO3·CH3OH (complex 1·MeOH) and tetranuclear complexes [Ln4(L1-c)2(L2)23-OH)2(NO3)2(CH3OH)4](NO3)2·2CH3CN·5CH3OH·2H2O (Ln = Dy, complex 2; Ln = Gd, complex 3). Magnetic susceptibility measurements show that 1·2H2O is a single-molecule magnet, 2 shows slow magnetic relaxation and 3 is a magnetic cooling material with the magnetic entropy change of 9.81 J kg−1 K−1 at 2 K and 5 T. The theoretical calculations on 1·MeOH indicate that it shows good magnetic anisotropy with the calculated energy barrier of 194.6 cm−1. Full article
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26 pages, 1794 KiB  
Review
Activating and Enhancing the Energy Flexibility Provided by a Pipe-Embedded Building Envelope: A Review
by Xiaochen Yang, Yanqing Li, Xiaoqiong Li, Khaled A. Metwally and Yan Ding
Buildings 2025, 15(15), 2793; https://doi.org/10.3390/buildings15152793 - 7 Aug 2025
Abstract
Building thermal mass offers a cost-effective solution to enhance the integration of energy supply and demand in dynamic energy systems. Thermally activated building systems (TABS), incorporating embedded heat tubes, shows strong potential for energy flexibility. However, the significant thermal inertia of TABS also [...] Read more.
Building thermal mass offers a cost-effective solution to enhance the integration of energy supply and demand in dynamic energy systems. Thermally activated building systems (TABS), incorporating embedded heat tubes, shows strong potential for energy flexibility. However, the significant thermal inertia of TABS also imposes challenges to precise load shift and indoor climate control. This review synthesizes key research on the effective demand-side management of TABS from multiple perspectives. It examines and compares various TABS configurations, including floor, ceiling, and wall systems. Differences in heat transfer performance between heating and cooling result in distinct application preferences for each type. The integration of advanced materials, such as phase change materials (PCM), can further enhance energy flexibility. TABS flexibility is primarily activated through adjustments to indoor operative temperature, with relevant influencing factors and regulatory constraints analyzed and discussed. Key aspects of optimizing building energy flexibility, including simulation methods and control strategies for TABS, are reviewed from both theoretical and practical perspectives. The energy and economic performance of TABS under various control strategies is analyzed in detail. This review provides insights to support the optimal design and operation of TABS within dynamic energy systems and to enhance the energy flexibility of building envelopes. Full article
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10 pages, 1801 KiB  
Article
Strong Radiative Cooling Coating Containing In Situ Grown TiO2/CNT Hybrids and Polyacrylic Acid Matrix
by Jiaziyi Wang, Yong Liu, Dapeng Liu, Yong Mu and Xilai Jia
Coatings 2025, 15(8), 921; https://doi.org/10.3390/coatings15080921 - 7 Aug 2025
Abstract
Traditional forced-air cooling systems suffer from excessive energy consumption and noise pollution. This study proposes an innovative passive cooling strategy through developing aqueous radiative cooling coatings made from a combination of TiO2-decorated carbon nanotube (TiO2-CNT) hybrids and polyacrylic acid [...] Read more.
Traditional forced-air cooling systems suffer from excessive energy consumption and noise pollution. This study proposes an innovative passive cooling strategy through developing aqueous radiative cooling coatings made from a combination of TiO2-decorated carbon nanotube (TiO2-CNT) hybrids and polyacrylic acid (PAA), designed to simultaneously enhance the heat dissipation and improve the mechanical strength of the coating films. Based on CNTs’ exceptional thermal conductivity and record-high infrared emissivity, bead-like TiO2-CNT architectures have been prepared as the filler in PAA. The TiO2 nanoparticles were in situ grown on CNTs, forming a rough surface that can produce asperity contacts and enhance the strength of the TiO2-CNT/PAA composite. Moreover, this composite enhanced heat dissipation and achieved remarkable cooling efficiency at a small fraction of the filler (0.1 wt%). The optimized coating demonstrated a temperature reduction of 23.8 °C at an operation temperature of 180.7 °C, coupled with obvious mechanical reinforcement (tensile strength from 13.7 MPa of pure PAA to 17.1 MPa). This work achieves the combination of CNT and TiO2 nanoparticles for strong radiative cooling coating, important for energy-efficient thermal management. Full article
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24 pages, 2863 KiB  
Article
An Integrated Bond Graph Methodology for Building Performance Simulation
by Abdelatif Merabtine
Energies 2025, 18(15), 4168; https://doi.org/10.3390/en18154168 - 6 Aug 2025
Abstract
Building performance simulation is crucial for the design and optimization of sustainable buildings. However, the increasing complexity of building systems necessitates advanced modeling techniques capable of handling multi-domain interactions. This paper presents a novel application of the bond graph (BG) methodology to simulate [...] Read more.
Building performance simulation is crucial for the design and optimization of sustainable buildings. However, the increasing complexity of building systems necessitates advanced modeling techniques capable of handling multi-domain interactions. This paper presents a novel application of the bond graph (BG) methodology to simulate and analyze the thermal behavior of an integrated trigeneration system within an experimental test cell. Unlike conventional simulation approaches, the BG framework enables unified modeling of thermal and hydraulic subsystems, offering a physically consistent and energy-based representation of system dynamics. The study investigates the system’s performance under both dynamic and steady-state conditions across two distinct climatic periods. Validation against experimental data reveals strong agreement between measured and simulated temperatures in heating and cooling scenarios, with minimal deviations. This confirms the method’s reliability and its capacity to capture transient thermal behaviors. The results also demonstrate the BG model’s effectiveness in supporting predictive control strategies, optimizing energy efficiency, and maintaining thermal comfort. By integrating hydraulic circuits and thermal exchange processes within a single modeling framework, this work highlights the potential of bond graphs as a robust and scalable tool for advanced building performance simulation. Full article
(This article belongs to the Section G: Energy and Buildings)
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51 pages, 4099 KiB  
Review
Artificial Intelligence and Digital Twin Technologies for Intelligent Lithium-Ion Battery Management Systems: A Comprehensive Review of State Estimation, Lifecycle Optimization, and Cloud-Edge Integration
by Seyed Saeed Madani, Yasmin Shabeer, Michael Fowler, Satyam Panchal, Hicham Chaoui, Saad Mekhilef, Shi Xue Dou and Khay See
Batteries 2025, 11(8), 298; https://doi.org/10.3390/batteries11080298 - 5 Aug 2025
Abstract
The rapid growth of electric vehicles (EVs) and new energy systems has put lithium-ion batteries at the center of the clean energy change. Nevertheless, to achieve the best battery performance, safety, and sustainability in many changing circumstances, major innovations are needed in Battery [...] Read more.
The rapid growth of electric vehicles (EVs) and new energy systems has put lithium-ion batteries at the center of the clean energy change. Nevertheless, to achieve the best battery performance, safety, and sustainability in many changing circumstances, major innovations are needed in Battery Management Systems (BMS). This review paper explores how artificial intelligence (AI) and digital twin (DT) technologies can be integrated to enable the intelligent BMS of the future. It investigates how powerful data approaches such as deep learning, ensembles, and models that rely on physics improve the accuracy of predicting state of charge (SOC), state of health (SOH), and remaining useful life (RUL). Additionally, the paper reviews progress in AI features for cooling, fast charging, fault detection, and intelligible AI models. Working together, cloud and edge computing technology with DTs means better diagnostics, predictive support, and improved management for any use of EVs, stored energy, and recycling. The review underlines recent successes in AI-driven material research, renewable battery production, and plans for used systems, along with new problems in cybersecurity, combining data and mass rollout. We spotlight important research themes, existing problems, and future drawbacks following careful analysis of different up-to-date approaches and systems. Uniting physical modeling with AI-based analytics on cloud-edge-DT platforms supports the development of tough, intelligent, and ecologically responsible batteries that line up with future mobility and wider use of renewable energy. Full article
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27 pages, 4509 KiB  
Article
Numerical Simulation and Analysis of Performance of Switchable Film-Insulated Photovoltaic–Thermal–Passive Cooling Module for Different Design Parameters
by Cong Jiao, Zeyu Li, Tiancheng Ju, Zihan Xu, Zhiqun Xu and Bin Sun
Processes 2025, 13(8), 2471; https://doi.org/10.3390/pr13082471 - 5 Aug 2025
Viewed by 145
Abstract
Photovoltaic–thermal (PVT) technology has attracted considerable attention for its ability to significantly improve solar energy conversion efficiency by simultaneously providing electricity and heat during the day. PVT technology serves a purpose in condensers and subcoolers for passive cooling in refrigeration systems at night. [...] Read more.
Photovoltaic–thermal (PVT) technology has attracted considerable attention for its ability to significantly improve solar energy conversion efficiency by simultaneously providing electricity and heat during the day. PVT technology serves a purpose in condensers and subcoolers for passive cooling in refrigeration systems at night. In our previous work, we proposed a switchable film-insulated photovoltaic–thermal–passive cooling (PVT-PC) module to address the structural incompatibility between diurnal and nocturnal modes. However, the performance of the proposed module strongly depends on two key design parameters: the structural height and the vacuum level of the air cushion. In this study, a numerical model of the proposed module is developed to examine the impact of design and meteorological parameters on its all-day performance. The results show that diurnal performance remains stable across different structural heights, while nocturnal passive cooling power shows strong dependence on vacuum level and structural height, achieving up to 103.73 W/m2 at 10 mm height and 1500 Pa vacuum, which is comparable to unglazed PVT modules. Convective heat transfer enhancement, induced by changes in air cushion shape, is identified as the primary contributor to improved nocturnal cooling performance. Wind speed has minimal impact on electrical output but significantly enhances thermal efficiency and nocturnal convective cooling power, with a passive cooling power increase of up to 31.61%. In contrast, higher sky temperatures degrade nocturnal cooling performance due to diminished radiative exchange, despite improving diurnal thermal efficiency. These findings provide fundamental insights for optimizing the structural design and operational strategies of PVT-PC systems under varying environmental conditions. Full article
(This article belongs to the Special Issue Numerical Simulation of Flow and Heat Transfer Processes)
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20 pages, 2385 KiB  
Article
Assessing Thermal Comfort in Green and Conventional Office Buildings in Hot Climates
by Abdulrahman Haruna Muhammad, Ahmad Taki and Sanober Hassan Khattak
Sustainability 2025, 17(15), 7078; https://doi.org/10.3390/su17157078 - 5 Aug 2025
Viewed by 69
Abstract
Green buildings are recognised for their potential to reduce energy consumption, minimise environmental impact, and improve occupants’ well-being, benefits that are especially critical in rapidly urbanising regions. However, questions remain about whether these buildings fully meet occupant comfort expectations while delivering energy efficiency. [...] Read more.
Green buildings are recognised for their potential to reduce energy consumption, minimise environmental impact, and improve occupants’ well-being, benefits that are especially critical in rapidly urbanising regions. However, questions remain about whether these buildings fully meet occupant comfort expectations while delivering energy efficiency. This is particularly relevant in Africa, where climate conditions and energy infrastructure challenges make sustainable building operation essential. Although interest in sustainable construction has increased, limited research has examined the real-world performance of green buildings in Africa. This study helps address that gap by evaluating indoor thermal comfort in a green-certified office building and two conventional office buildings in Abuja, Nigeria, through post-occupancy evaluation (POE). The Predicted Mean Vote (PMV) and Thermal Sensation Vote (TSV) were used to assess comfort, revealing discrepancies between predicted and actual occupant responses. In the green building, PMV indicated near-neutral conditions (0.28), yet occupants reported a slightly cool sensation (TSV: −1.1). Neutral temperature analysis showed that the TSV-based neutral temperature (26.5 °C) was 2.2 °C higher than the operative temperature (24.3 °C), suggesting overcooling. These findings highlight the importance of incorporating occupant feedback into HVAC control. Aligning cooling setpoints with comfort preferences could improve satisfaction and reduce unnecessary cooling, promoting energy-efficient building operation. Full article
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27 pages, 1491 KiB  
Article
Spent Nuclear Fuel—Waste to Resource, Part 1: Effects of Post-Reactor Cooling Time and Novel Partitioning Strategies in Advanced Reprocessing on Highly Active Waste Volumes in Gen III(+) UOx Fuel Systems
by Alistair F. Holdsworth, Edmund Ireland and Harry Eccles
J. Nucl. Eng. 2025, 6(3), 29; https://doi.org/10.3390/jne6030029 - 5 Aug 2025
Viewed by 205
Abstract
Some of nuclear power’s primary detractors are the unique environmental challenges and impacts of radioactive wastes generated during fuel cycle operations. Key benefits of spent fuel reprocessing (SFR) are reductions in primary high active waste (HAW) masses, volumes, and lengths of radiotoxicity at [...] Read more.
Some of nuclear power’s primary detractors are the unique environmental challenges and impacts of radioactive wastes generated during fuel cycle operations. Key benefits of spent fuel reprocessing (SFR) are reductions in primary high active waste (HAW) masses, volumes, and lengths of radiotoxicity at the expense of secondary waste generation and high capital and operational costs. By employing advanced waste management and resource recovery concepts in SFR beyond the existing standard PUREX process, such as minor actinide and fission product partitioning, these challenges could be mitigated, alongside further reductions in HAW volumes, masses, and duration of radiotoxicity. This work assesses various current and proposed SFR and fuel cycle options as base cases, with further options for fission product partitioning of the high heat radionuclides (HHRs), rare earths, and platinum group metals investigated. A focus on primary waste outputs and the additional energy that could be generated by the reprocessing of high-burnup PWR fuel from Gen III(+) reactors using a simple fuel cycle model is used; the effects of 5- and 10-year spent fuel cooling times before reprocessing are explored. We demonstrate that longer cooling times are preferable in all cases except where short-lived isotope recovery may be desired, and that the partitioning of high-heat fission products (Cs and Sr) could allow for the reclassification of traditional raffinates to intermediate level waste. Highly active waste volume reductions approaching 50% vs. PUREX raffinate could be achieved in single-target partitioning of the inactive and low-activity rare earth elements, and the need for geological disposal could potentially be mitigated completely if HHRs are separated and utilised. Full article
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24 pages, 4314 KiB  
Article
Hyperparameter Optimization of Neural Networks Using Grid Search for Predicting HVAC Heating Coil Performance
by Yosef Jaber, Pasidu Dharmasena, Adam Nassif and Nabil Nassif
Buildings 2025, 15(15), 2753; https://doi.org/10.3390/buildings15152753 - 5 Aug 2025
Viewed by 200
Abstract
Heating, Ventilation, and Air Conditioning (HVAC) systems represent a significant portion of global energy use, yet they are often operated without optimized control strategies. This study explores the application of deep learning to accurately model heating system behavior as a foundation for predictive [...] Read more.
Heating, Ventilation, and Air Conditioning (HVAC) systems represent a significant portion of global energy use, yet they are often operated without optimized control strategies. This study explores the application of deep learning to accurately model heating system behavior as a foundation for predictive control and energy-efficient HVAC operation. Experimental data were collected under controlled laboratory conditions, and 288 unique hyperparameter configurations were developed. Each configuration was tested three times, resulting in a total of 864 artificial neural network models. Five key hyperparameters were varied systematically: number of epochs, network size, network shape, learning rate, and optimizer. The best-performing model achieved a mean squared error of 0.469 and featured 17 hidden layers, a left-triangle architecture trained for 500 epochs with a learning rate of 5 × 10−5, and Adam as the optimizer. The results highlighted the importance of hyperparameter tuning in improving model accuracy. Future research should extend the analysis to incorporate cooling operation and real-world building operation data for broader applicability. Full article
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33 pages, 879 KiB  
Article
Barrier Analysis of Flexibilization of Cooling Supply Systems
by Dana Laureen Laband, Martin Stöckl, Annedore Mittreiter and Uwe Holzhammer
Energies 2025, 18(15), 4133; https://doi.org/10.3390/en18154133 - 4 Aug 2025
Viewed by 96
Abstract
The present study examines the barriers that prevent cooling system flexibility from being optimized. In the context of an increasing reliance on renewable energy sources, the necessity for flexible energy utilization is becoming increasingly apparent. A survey and discussion groups were conducted with [...] Read more.
The present study examines the barriers that prevent cooling system flexibility from being optimized. In the context of an increasing reliance on renewable energy sources, the necessity for flexible energy utilization is becoming increasingly apparent. A survey and discussion groups were conducted with various stakeholders within the cooling value chain to obtain their experiences and insights regarding barriers to flexibilization. The findings point out that economic, technological, and regulatory barriers are the primary factors impeding the implementation of flexible solutions. In particular, high investment costs, complex technical implementation, a lack of information, and a complicated legal framework were identified as significant impediments. To enhance the flexibility of cooling systems, coordinated efforts are necessary to address these barriers. Practical examples, training, and the standardization and digitalization of processes could facilitate the widespread implementation of flexible cooling systems. Full article
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27 pages, 6022 KiB  
Review
Hydrogen Cryomagnetic a Common Solution for Metallic and Oxide Superconductors
by Bartlomiej Andrzej Glowacki
Materials 2025, 18(15), 3665; https://doi.org/10.3390/ma18153665 - 4 Aug 2025
Viewed by 116
Abstract
This article examines the physical properties, performance metrics, and cooling requirements of a range of superconducting materials, with a particular focus on their compatibility with hydrogen-based cryogenic systems. It analyses recent developments and challenges in this field, and considers how hydrogen cryomagnetic could [...] Read more.
This article examines the physical properties, performance metrics, and cooling requirements of a range of superconducting materials, with a particular focus on their compatibility with hydrogen-based cryogenic systems. It analyses recent developments and challenges in this field, and considers how hydrogen cryomagnetic could transform superconducting technologies, making them economically viable and environmentally sustainable for a variety of critical applications. The discussion aims to provide insights into the intersection of metallic and ceramic superconductors with the hydrogen economy and to chart a path towards scalable and impactful solutions in the energy sector. Full article
(This article belongs to the Special Issue Advanced Superconducting Materials and Technology)
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32 pages, 3972 KiB  
Article
A Review and Case of Study of Cooling Methods: Integrating Modeling, Simulation, and Thermal Analysis for a Model Based on a Commercial Electric Permanent Magnet Synchronous Motor
by Henrry Gabriel Usca-Gomez, David Sebastian Puma-Benavides, Victor Danilo Zambrano-Leon, Ramón Castillo-Díaz, Milton Israel Quinga-Morales, Javier Milton Solís-Santamaria and Edilberto Antonio Llanes-Cedeño
World Electr. Veh. J. 2025, 16(8), 437; https://doi.org/10.3390/wevj16080437 - 4 Aug 2025
Viewed by 159
Abstract
The efficiency of electric motors is highly dependent on their operating temperature, with lower temperatures contributing to enhanced performance, reliability, and extended service life. This study presents a comprehensive review of state-of-the-art cooling technologies and evaluates their impact on the thermal behavior of [...] Read more.
The efficiency of electric motors is highly dependent on their operating temperature, with lower temperatures contributing to enhanced performance, reliability, and extended service life. This study presents a comprehensive review of state-of-the-art cooling technologies and evaluates their impact on the thermal behavior of a commercial motor–generator system in high-demand applications. A baseline model of a permanent magnet synchronous motor (PMSM) was developed using MotorCAD 2023® software, which was supported by reverse engineering techniques to accurately replicate the motor’s physical and thermal characteristics. Subsequently, multiple cooling strategies were simulated under consistent operating conditions to assess their effectiveness. These strategies include conventional axial water jackets as well as advanced oil-based methods such as shaft cooling and direct oil spray to the windings. The integration of these systems in hybrid configurations was also explored to maximize thermal efficiency. Simulation results reveal that hybrid cooling significantly reduces the temperature of critical components such as stator windings and permanent magnets. This reduction in thermal stress improves current efficiency, power output, and torque capacity, enabling reliable motor operation across a broader range of speeds and under sustained high-load conditions. The findings highlight the effectiveness of hybrid cooling systems in optimizing both thermal management and operational performance of electric machines. Full article
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50 pages, 9033 KiB  
Article
Heat Pipe Integrated Cooling System of 4680 Lithium–Ion Battery for Electric Vehicles
by Yong-Jun Lee, Tae-Gue Park, Chan-Ho Park, Su-Jong Kim, Ji-Su Lee and Seok-Ho Rhi
Energies 2025, 18(15), 4132; https://doi.org/10.3390/en18154132 - 4 Aug 2025
Viewed by 213
Abstract
This study investigates a novel heat pipe integrated cooling system designed for thermal management of Tesla’s 4680 cylindrical lithium–ion batteries in electric vehicles (EVs). Through a comprehensive approach combining experimental analysis, 1-D AMESim simulations, and 3-D Computational Fluid Dynamics (CFD) modeling, the thermal [...] Read more.
This study investigates a novel heat pipe integrated cooling system designed for thermal management of Tesla’s 4680 cylindrical lithium–ion batteries in electric vehicles (EVs). Through a comprehensive approach combining experimental analysis, 1-D AMESim simulations, and 3-D Computational Fluid Dynamics (CFD) modeling, the thermal performance of various wick structures and working fluid filling ratios was evaluated. The experimental setup utilized a triangular prism chamber housing three surrogate heater blocks to replicate the heat generation of 4680 cells under 1C, 2C, and 3C discharge rates. Results demonstrated that a blended fabric wick with a crown-shaped design (Wick 5) at a 30–40% filling ratio achieved the lowest maximum temperature (Tmax of 47.0°C), minimal surface temperature deviation (ΔTsurface of 2.8°C), and optimal thermal resistance (Rth of 0.27°C/W) under 85 W heat input. CFD simulations validated experimental findings, confirming stable evaporation–condensation circulation at a 40% filling ratio, while identifying thermal limits at high heat loads (155 W). The proposed hybrid battery thermal management system (BTMS) offers significant potential for enhancing the performance and safety of high-energy density EV batteries. This research provides a foundation for optimizing thermal management in next-generation electric vehicles. Full article
(This article belongs to the Special Issue Optimized Energy Management Technology for Electric Vehicle)
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