Search Results (1,383)

With the widespread use of lithium-ion batteries in electric vehicles, energy storage systems, and portable electronic devices, concerns regarding their thermal runaway have escalated, raising significant safety issues. Despite advances in existing thermal management technologies, challenges remain in addressing the complexity and variability of battery thermal runaway. These challenges include the limited heat dissipation capability of passive thermal management, the high energy consumption of active thermal management, and the ongoing optimization of material improvement methods. This paper systematically examines the mechanisms through which three main triggers—mechanical abuse, thermal abuse, and electrical abuse—affect the thermal runaway of lithium-ion batteries. It also reviews the advantages and limitations of passive and active thermal management techniques, battery management systems, and material improvement strategies for enhancing the thermal stability of batteries. Additionally, a comparison of the principles, characteristics, and innovative examples of various thermal management technologies is provided in tabular form. The study aims to offer a theoretical foundation and practical guidance for optimizing lithium-ion battery thermal management technologies, thereby promoting their development for high-safety and high-reliability applications. Full article

The increasing depletion of fossil fuels and their environmental impact have led to the development of fuel cell hybrid electric vehicles. By combining fuel cells with batteries, these vehicles offer greater efficiency and zero emissions. However, their energy management remains a challenge requiring advanced strategies. This paper presents a comparative study of two developed energy management strategies: a deterministic rule-based approach and a fuzzy logic approach. The proposed system consists of a proton exchange membrane fuel cell (PEMFC) as the primary energy source and a lithium-ion battery as the secondary source. A comprehensive model of the hybrid powertrain is developed to evaluate energy distribution and system behaviour. The control system includes a model predictive control (MPC) method for fuel cell current regulation and a PI controller to maintain DC bus voltage stability. The proposed strategies are evaluated under standard driving cycles (UDDS and NEDC) using a simulation in MATLAB/Simulink. Key performance indicators such as fuel efficiency, hydrogen consumption, battery state-of-charge, and voltage stability are examined to assess the effectiveness of each approach. Simulation results demonstrate that the deterministic strategy offers a structured and computationally efficient solution, while the fuzzy logic approach provides greater adaptability to dynamic driving conditions, leading to improved overall energy efficiency. These findings highlight the critical role of advanced control strategies in improving FCHEV performance and offer valuable insights for future developments in hybrid-vehicle energy management. Full article

Determining charge and discharge behavior is essential for optimizing charging strategies and evaluating balancing algorithms in battery energy storage systems and electric vehicles. Conventionally, a sequence of circuit simulations or tedious hardware tests is required to evaluate the performance of the balancing algorithm. To mitigate these problems, this paper proposes a variable capacitor model that can be easily built from the incremental capacity curve. This model provides a direct and insightful R-C time constant method for the charge/discharge time calculation. After validating the model accuracy by experimental results based on the cylindrical lithium-ion cell test, a switched-capacitor active balancing and a passive cell balancing circuit are implemented to further verify the effectiveness of the proposed model in calculating the cell balancing time within 2% error. Full article

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

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 (T_max of 47.0°C), minimal surface temperature deviation (ΔT_surface of 2.8°C), and optimal thermal resistance (R_th 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

The energy generated from renewable sources has an intermittent nature since solar irradiation and wind speed vary continuously. Hence, their energy should be stored to be utilized throughout their shortage. There are various forms of energy storage systems while the most widespread technique is the battery storage system since its cost is low compared to other techniques. Therefore, batteries are employed in several applications like power systems, electric vehicles, and smart grids. Due to the merits of the lithium-ion (Li-ion) battery, it is preferred over other kinds of batteries. However, the accuracy of the Li-ion battery model is essential for estimating the state of charge (SOC). Additionally, it is essential for consistent simulation and operation throughout various loading and charging conditions. Consequently, the determination of real battery model parameters is vital. An innovative application of the red-billed blue magpie optimizer (RBMO) for determining the model parameters and the SOC of the Li-ion battery is presented in this article. The Shepherd model parameters are determined using the suggested optimization algorithm. The RBMO-based modeling approach offers excellent execution in determining the parameters of the battery model. The suggested approach is compared to other programmed algorithms, namely dandelion optimizer, spider wasp optimizer, barnacles mating optimizer, and interior search algorithm. Moreover, the suggested RBMO is statistically evaluated using Kruskal–Wallis, ANOVA tables, Friedman rank, and Wilcoxon rank tests. Additionally, the Li-ion battery model estimated via the RBMO is validated under variable loading conditions. The fetched results revealed that the suggested approach achieved the least errors between the measured and estimated voltages compared to other approaches in two studied cases with values of 1.4951 × 10⁻⁴ and 2.66176 × 10⁻⁴. Full article

The improvement of environmental conditions has become a priority for governments and legislators. New electrified mobility systems are increasingly present in our environment, as they enable the reduction of polluting emissions. Electric vehicles (EVs) are one of the fastest-growing alternatives to date, with exponential growth expected over the next few years. In this article, the various charging modes for EVs are explored, and the risks associated with charging technologies are analysed, particularly for charging systems in high-power DC with Lithium battery energy storage, given their long market deployment and characteristic behaviour. In particular, the Arc Flash (AF) risk present in high-power DC chargers will be studied, involving numerous simulations of the charging process. Subsequently, the Incident Energy (IE) analysis is carried out at different specific points of a commercial high-power ‘Mode 4’ charger. For this purpose, different analysis methods of recognised prestige, such as Doan, Paukert, or Stokes and Oppenlander, are applied, using the latest version of the ETAP^® simulation tool version 22.5.0. This study focuses on quantifying the potential severity (consequences) of an AF event, assuming its occurrence, rather than performing a probabilistic risk assessment according to standard methodologies. The primary objective of this research is to comprehensively quantify the potential consequences for workers involved in the operation, maintenance, repair, and execution of tasks related to EV charging systems. This analysis makes it possible to provide safe working conditions and to choose the appropriate and necessary personal protective equipment (PPE) for each type of operation. It is essential to develop this novel process to quantify the consequences of AF and to protect the end users of EV charging systems. Full article

The transition to electric mobility has significantly increased the demand for lithium-ion batteries, raising concerns about their end-of-life management. Therefore, this study presents the design, development and first implementation steps of a stationary energy storage system utilizing second-life electric vehicle (EV) batteries. These batteries, no longer suitable for traction applications due to a reduced state of health (SoH) below 80%, retain sufficient capacity for less demanding stationary applications. The proposed system is designed to be flexible and scalable, serving both research and commercial purposes. Key challenges include heterogeneous battery characteristics, safety considerations due to increased internal resistance and battery aging, and the need for flexible power electronics. An optimized dual active bridge (DAB) converter topology is introduced to connect several batteries in parallel and to ensure efficient bidirectional power flow over a wide voltage range. A first prototype, rated at 50 $\mathrm{k}$$\mathrm{W}$, has been built and tested in the laboratory. This study contributes to sustainable energy storage solutions by extending battery life cycles, reducing waste, and promoting economic viability for industrial partners. Full article

This study presents a hybrid method for state-of-charge (SOC) estimation of lithium-ion batteries using LSTM neural networks optimized with genetic algorithms (GA), combined with Coulomb Counting (CC) as an initial estimator. Experimental tests were conducted using medium-voltage (48–72 V) lithium-ion battery packs under standardized driving cycles (NEDC and WLTP). The proposed method enhances prediction accuracy under dynamic conditions by recalibrating the LSTM output with CC estimates through a dynamic fusion parameter $\alpha$. The novelty of this approach lies in the integration of machine learning and physical modeling, optimized via evolutionary algorithms, to address limitations of standalone methods in real-time applications. The hybrid model achieved a mean absolute error (MAE) of 0.181%, outperforming conventional estimation strategies. These findings contribute to more reliable battery management systems (BMS) for electric vehicles and second-life applications. Full article

This study aims to develop a method for analyzing real-world battery degradation in electric vehicles in order to identify the optimal battery management system (BMS) during the early digital phase of vehicle development. Battery management of lithium-ion batteries (LiBs) in electric vehicles is important to ensure a stable output and to counteract degradation and thermal runaway. To design the optimal system, it is most effective to use a 1D (one-dimensional) vehicle system simulation model, which connects each unit model inside the vehicle, due to the system’s complexity. In order to create a long-term degradation simulation in a vehicle system model, it is important to reduce computational load. Therefore, in this paper, we studied a suitable battery degradation calculation for the vehicle system model based on an equivalent circuit model (ECM) and degradation approximation formulas. After implementing these models, we analyzed long-term degradation behavior through the real-world operation of an electric vehicle driver. We first implemented a high-accuracy ECM using transient charge–discharge tests and Bayesian Optimization. Next, we formulated approximation formulas for degradation prediction based on calendar and cycle degradation tests. Finally, we simulated real-world degradation behavior using these models. The simulation results revealed that even for users who frequently use electric vehicles, degradation under storage conditions is the dominant factor in overall degradation. Full article

The accurate estimation and prediction of internal states in lithium-ion (Li-Ion) batteries, such as State of Charge (SoC) and Remaining Useful Life (RUL), are vital for optimizing battery performance, safety, and longevity in electric vehicles and other applications. This paper presents a unified, modular, and extensible machine learning (ML) framework designed to address the heterogeneity and complexity of battery state prediction tasks. The proposed framework supports flexible configurations across multiple dimensions, including feature engineering, model selection, and training/testing strategies. It integrates standardized data processing pipelines with a diverse set of ML models, such as a long short-term memory neural network (LSTM), a convolutional neural network (CNN), a feedforward neural network (FFNN), automated machine learning (AutoML), and classical regressors, while accommodating heterogeneous datasets. The framework’s applicability is demonstrated through five distinct use cases involving SoC estimation and RUL prediction using real-world and benchmark datasets. Experimental results highlight the framework’s adaptability, methodological transparency, and robust predictive performance across various battery chemistries, usage profiles, and degradation conditions. This work contributes to a standardized approach that facilitates the reproducibility, comparability, and practical deployment of ML-based battery analytics. Full article

Given the rising importance of cost-effective solutions in battery research, this study employs an accessible testing approach using low-cost, sensor-equipped platforms that enable broader research and educational applications. It presents a comparative evaluation of lithium-ion battery degradation under two charging strategies: static charging (constant current at 1.2 A) and dynamic charging (stepped current from 400 mA to 800 mA) over 200 charge–discharge cycles. A custom-built, low-cost test platform based on an ESP32 microcontroller was developed to provide real-time monitoring of voltage, current, temperature, and internal resistance, with automated control and cloud-based data logging. The results indicate that static charging provides greater voltage stability and a lower increase in internal resistance (9.3%) compared to dynamic charging (30.17%), suggesting reduced electrochemical stress. Discharge time decreased for both strategies, by 6.25% under static charging and 18.46% under dynamic charging, highlighting capacity fade and aging effects. Internal resistance emerged as a reliable indicator of degradation, closely correlating with reduced runtime. These findings underscore the importance of selecting charging profiles based on specific application needs, as dynamic charging, while offering potential thermal benefits, may accelerate battery aging. Furthermore, the low-cost testing platform proved effective for long-term evaluation and degradation analysis, offering an accessible alternative to commercial battery cyclers. The insights gained contribute to the development of adaptive battery management systems that optimize performance, lifespan, and safety in electric vehicle applications. Full article

As global climate change intensifies and the transition to clean energy accelerates, lithium-ion batteries—critical components of electric vehicles—are becoming increasingly vital in international trade networks. This study investigates the structural evolution and determinants of the electric vehicle lithium-ion battery trade network among European Union (EU) member states from 2012 to 2023, employing social network analysis and the multiple regression quadratic assignment procedure method. The findings demonstrate the transformation of the network from a centralized and loosely connected structure, with Germany as the dominant hub, to a more interconnected and decentralized system in which Poland and Hungary emerge as the leading players. Key network metrics, such as the density, clustering coefficients, and average path lengths, reveal increased regional trade connectivity and enhanced supply chain efficiency. The analysis identifies geographic and economic proximity, logistics performance, labor cost differentials, energy resource availability, and venture capital investment as significant drivers of trade flows, highlighting the interaction among spatial, economic, and infrastructural factors in shaping the network. Based on these findings, this study underscores the need for targeted policy measures to support Central and Eastern European countries, including investment in logistics infrastructure, technological innovation, and regional cooperation initiatives, to strengthen their integration into the supply chain and bolster their export capacity. Furthermore, fostering balanced inter-regional collaborations is essential in building a resilient trade network. Continued investment in transportation infrastructure and innovation is recommended to sustain the EU’s competitive advantage in the global electric vehicle lithium-ion battery supply chain. Full article

The transition to electric vehicles (EVs) is accelerating due to global efforts to reduce greenhouse gas emissions and reliance on fossil fuels. Lithium-ion batteries (LIBs) are the predominant energy storage solution in EVs, offering high energy density, efficiency, and long lifespan. However, their adoption is overly involved with critical safety concerns, including thermal runaway and overheating. This review systematically focuses on the critical role of battery thermal management systems (BTMSs), such as active, passive, and hybrid cooling systems, in maintaining LIBs within their optimal operating temperature range, ensuring temperature homogeneity, safety, and efficiency. Additionally, the study explores the impact of integrating artificial intelligence (AI) and machine learning (ML) into BTMS on thermal performance prediction and energy-efficient cooling, focusing on optimizing the operating parameters of cooling systems. This review provides insights into enhancing LIB safety and performance for widespread EV adoption by addressing these challenges. Full article

Remaining useful life (RUL) serves as a pivotal metric for quantifying lithium-ion batteries’ state of health (SOH) in electric vehicles and plays a crucial role in ensuring their safety and reliability. In order to achieve accurate and reliable RUL prediction, a novel RUL prediction method which employs a back propagation (BP) neural network based on the Harris Hawks optimization (HHO) algorithm is proposed. This method optimizes the BP parameters using the improved HHO algorithm. At first, the circle chaotic mapping method is utilized to solve the problem of the initial value. Considering the problem of local convergence, Gaussian mutation is introduced to improve the search ability of the algorithm. Subsequently, two key health factors are selected as input features for the model, including the constant-current charging isovoltage rise time and constant-current discharging isovoltage drop time. The model is validated using aging data from commercial lithium iron phosphate (LiFePO₄) batteries. Finally, the model is thoroughly verified under an aging test. Experimental validation using training sets comprising 50%, 60%, and 70% of the cycle data demonstrates superior predictive performance, with mean absolute error (MAE) values below 0.012, root mean square error (RMSE) values below 0.017 and mean absolute percentage error (MAPE) within 0.95%. The results indicate that the model significantly improves prediction accuracy, robustness and searchability. Full article