Search Results (3,451)

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

Electric motors play a decisive role in electric vehicles by converting electrical energy into mechanical motion across various drivetrain components. However, failures in these motors can interrupt the motor function, with approximately 40% of these failures stemming from bearing issues. Key contributors to bearing degradation include shaft voltage, bearing current, and electric discharge material spalling current, especially in motors powered by inverters or variable frequency drives. This review explores the tribological and vibrational aspects of bearing currents, analyzing their mechanisms and influence on electric motor performance. It addresses the challenges faced by electric vehicles, such as high-speed operation, elevated temperatures, electrical conductivity, and energy efficiency. This study investigates the origins of bearing currents, damage linked to shaft voltage and electric discharge material spalling current, and the effects of lubricant properties on bearing functionality. Moreover, it covers various methods for measuring shaft voltage and bearing current, as well as strategies to alleviate the adverse impacts of bearing currents. This comprehensive analysis aims to shed light on the detrimental effects of bearing currents on the performance and lifespan of electric motors in electric vehicles, emphasizing the importance of tribological considerations for reliable operation and durability. The aim of this study is to address the engineering problem of bearing failure in inverter-fed EV motors by integrating electrical, tribological, and lubrication perspectives. The novelty lies in proposing a conceptual link between lubricant breakdown and damage morphology to guide mitigation strategies. The study tasks include literature review, analysis of bearing current mechanisms and diagnostics, and identification of technological trends. The findings provide insights into lubricant properties and diagnostic approaches that can support industrial solutions. 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

This paper presents an advanced energy management system (EMS) for optimizing power distribution in a battery/ultracapacitor (UC) hybrid energy storage system (HESS) for electric vehicles (EVs). The proposed EMS accounts for all energy flow scenarios within a practical driving cycle. A regenerative braking control strategy is developed to maximize kinetic energy recovery using an induction motor, efficiently distributing the recovered energy between the UC and battery. Additionally, a power flow management approach is introduced for both motoring (discharge) and braking (charge) operations via bidirectional buck–boost DC-DC converters. In discharge mode, an optimal distribution factor is dynamically adjusted to balance power delivery between the battery and UC, maximizing efficiency. During charging, a DC link voltage control mechanism prioritizes UC charging over the battery, reducing stress and enhancing energy recovery efficiency. The proposed EMS is validated through simulations and experiments, demonstrating significant improvements in vehicle acceleration, energy efficiency, and battery lifespan. Full article

The (1−x)Ba_0.96Ca_0.04TiO₃−xBi(Li_1/3Zr_2/3)O₃ (x = 0.03–0.15) ceramics were fabricated via the traditional solid reaction method. Characterization results revealed that each component exhibited a pure perovskite structure, and the average grain size significantly diminishes with increasing x. The (1−x)Ba_0.96Ca_0.04TiO₃−xBi(Li_1/3Zr_2/3)O₃ ceramics exhibited prominent relaxor ferroelectric behavior, whose characteristic narrow hysteresis loops effectively enhanced the energy storage performance of the material. Most importantly, the composition with x = 0.10 demonstrated exceptional energy storage properties at 150 kV/cm, achieving a high recoverable energy storage density (W_rec = 1.91 J/cm³) and excellent energy efficiency (η = 90.87%). Under the equivalent electric field, this composition also displayed a superior pulsed discharge performance, including a high current density (871 A/cm²), a high power density (67.3 MW/cm³), an ultrafast discharge time (t_0.9 = 109 ns), and a discharged energy density of 1.47 J/cm³. These results demonstrate that the (1−x)Ba_0.96Ca_0.04TiO₃−xBi(Li_1/3Zr_2/3)O₃ ceramic system establishes a promising design paradigm for the creation and refinement of next-generation dielectrics for pulse power applications. Full article

With the electrification of generator sets, electric locomotives, new energy vehicles, and other industries, AC motors subject bearings to an electric field environment, leading to galvanic corrosion due to the use of variable frequency power supply drives. The phenomenon of bearing discharge breakdown in subway traction motors is a critical issue in understanding the relationship between shaft current strength and the extent of bearing damage. This paper analyzes the mechanism of impulse discharge that leads to galvanic corrosion damage in bearings at a microscopic level and conducts electric thermal coupling simulations of the traction motor bearing discharge breakdown process. It examines the temperature rise associated with lubricant film discharge breakdown during the dynamic operation of the bearing and investigates how breakdown channel parameters and operational conditions affect the temperature rise in the micro-region of bearing lubrication. Ultimately, the results of the electric thermal coupling simulation are validated through experimental tests. This study revealed that in an electric field environment, the load-bearing area of the outer ring experiences significantly more severe corrosion damage than the inner ring, whereas non-bearing areas remain unaffected by electrolytic corrosion. When the inner ring reaches a speed of 4500_rpm, the maximum widths of electrolytic corrosion pits for the outer and inner rings are measured at 89 um and 51 um, respectively. Additionally, the highest recorded temperatures for the breakdown channels in the outer and inner rings are 932 °C and 802 °C, respectively. Furthermore, as the inner ring speed increases, both the width of the electrolytic corrosion pits and the temperature of the breakdown channels rise. Specifically, at inner ring speeds of 2500_rpm, 3500_rpm, and 4500_rpm, the widths of the electrolytic pits in the outer ring raceway load zone were measured at 34 um, 56 um, and 89 um, respectively. The highest temperatures of the lubrication film breakdown channels were recorded as 612 °C, 788 °C, and 932 °C, respectively. This study provides a theoretical basis and data support for the protective and maintenance practices of traction motor bearings. Full article

With the support of the dual-carbon strategy and related policies, China’s offshore wind power has experienced rapid development. However, constrained by the inherent intermittency and volatility of wind power, large-scale expansion poses significant challenges to grid integration and exacerbates government fiscal burdens. To address these critical issues, this paper proposes a multi-market coupling trading model integrating energy storage-equipped offshore wind power into electricity–carbon–green certificate markets for large-scale grid networks. Firstly, a day-ahead electricity market optimization model that incorporates energy storage is established to maximize power revenue by coordinating offshore wind power generation, thermal power dispatch, and energy storage charging/discharging strategies. Subsequently, carbon market and green certificate market optimization models are developed to quantify Chinese Certified Emission Reduction (CCER) volume, carbon quotas, carbon emissions, market revenues, green certificate quantities, pricing mechanisms, and associated economic benefits. To validate the model’s effectiveness, a gradient ascent-optimized game-theoretic model and a double auction mechanism are introduced as benchmark comparisons. The simulation results demonstrate that the proposed model increases market revenues by 17.13% and 36.18%, respectively, compared to the two benchmark models. It not only improves wind power penetration and comprehensive profitability but also effectively alleviates government subsidy pressures through coordinated carbon–green certificate trading mechanisms. Full article

Hydrogen production is increasingly vital for global decarbonization but remains a water- and energy-intensive process, especially in arid regions. Despite growing attention to its climate benefits, limited research has addressed the environmental impacts of water sourcing. This study employs a life cycle assessment (LCA) approach to evaluate three water supply strategies for hydrogen production: (1) seawater desalination without brine treatment (BT), (2) desalination with partial BT, and (3) freshwater purification. Scenarios are modeled for the United Arab Emirates (UAE), Australia, and Spain, representing diverse electricity mixes and water stress conditions. Both electrolysis and steam methane reforming (SMR) are evaluated as hydrogen production methods. Results show that desalination scenarios contribute substantially to human health and ecosystem impacts due to high energy use and brine discharge. Although partial BT aims to reduce direct marine discharge impacts, its substantial energy demand can offset these benefits by increasing other environmental burdens, such as marine eutrophication, especially in regions reliant on carbon-intensive electricity grids. Freshwater scenarios offer lower environmental impact overall but raise water availability concerns. Across all regions, feedwater for SMR shows nearly 50% lower impacts than for electrolysis. This study focuses solely on the environmental impacts associated with water sourcing and treatment for hydrogen production, excluding the downstream impacts of the hydrogen generation process itself. This study highlights the trade-offs between water sourcing, brine treatment, and freshwater purification for hydrogen production, offering insights for optimizing sustainable hydrogen systems in water-stressed regions. Full article

Magnetic gears (MGs) are attracting increasing attention in power transmission systems due to their contactless operation principles, low frictional losses, and high efficiency. However, the broad application potential of these technologies requires a comprehensive evaluation of engineering parameters, such as material selection, energy efficiency, and structural design. This review focuses solely on solid-core magnetic gear systems designed using laminated electrical steels, soft magnetic composites (SMCs), and high-saturation alloys. This review systematically examines the topological diversity, torque transmission principles, and the impact of various core materials, such as electrical steels, soft magnetic composites (SMCs), and cobalt-based alloys, on the performance of magnetic gear systems. Literature-based comparative analyses are structured around topological classifications, evaluation of material properties, and performance analyses based on losses. Additionally, the study highlights that aligning material properties with appropriate manufacturing methods, such as powder metallurgy, wire electrical discharge machining (EDM), and precision casting, is essential for the practical scalability of magnetic gear systems. The findings reveal that coaxial magnetic gears (CMGs) offer a favorable balance between high torque density and compactness, while soft magnetic composites provide significant advantages in loss reduction, particularly at high frequencies. Additionally, application trends in fields such as renewable energy, electric vehicles (EVs), aerospace, and robotics are highlighted. Full article

This study presents the first investigation into the application of ultrasonic vibration-assisted electrical discharge machining (UV-EDM) using graphite electrodes for external cylindrical surface machining—an essential surface in the production of tablet punches and sheet metal-forming dies. A custom ultrasonic horn was designed and fabricated using 90CrSi material to operate effectively at a resonant frequency of 20 kHz, ensuring stable vibration transmission throughout the machining process. A Box–Behnken experimental design was employed to explore the effects of five process parameters—vibration amplitude (A), pulse-on time (Ton), pulse-off time (Toff), discharge current (Ip), and servo voltage (SV)—on two key performance indicators: material removal rate (MRR) and surface roughness (Ra). The optimization process was conducted in two stages: single-objective analysis to maximize MRR while ensuring Ra < 4 µm, followed by a hybrid multi-objective approach combining NSGA-II and the Analytic Hierarchy Process (AHP). The optimal solution achieved a high MRR of 9.28 g/h while maintaining Ra below the critical surface finish threshold, thus meeting the practical requirements for punch surface quality. The findings confirm the effectiveness of the proposed horn design and hybrid optimization strategy, offering a new direction for enhancing productivity and surface integrity in cylindrical EDM applications using graphite electrodes. Full article

The increasing utilization of hard-to-cut materials in high-performance sectors such as aerospace and defense has pushed manufacturing systems to be flexible in processing large workpieces with a wide range of materials while also delivering high precision. Recent studies have highlighted the potential of integrating industrial robots (IRs) with electric discharge machining (EDM) to create a non-contact, low-force manufacturing platform, particularly suited for the accurate machining of hard-to-cut materials into complex and large-scale monolithic components. In response to this potential, a novel robotic EDM system has been developed. However, the manual programming and control of such a convoluted system present a significant challenge, often leading to inefficiencies and increased error rates, creating a scenario where the EDM process becomes unfeasible. To enhance the industrial applicability of this robotic EDM technology, this study focuses on a novel methodology to develop and validate a digital twin (DT) of the physical robotic EDM system. The digital twin functions as a virtual experimental environment for tool motion, effectively addressing the challenges posed by collisions and kinematic singularities inherent in the physical system, yet with proven 20-micron EDM gap accuracy. Furthermore, it facilitates a CNC-like, user-friendly offline programming framework for robotic EDM cutting path generation. Full article

This study focuses on the evaluation of electrical stress limit capability for 3D-packaged memory (256 M × 72-bit DDR3 SDRAM) (Shanghai Fudan Microelectronics Group Co., Ltd., Shanghai, China). Guided by Reliability Enhancement Theory, this study presents a meticulously designed comprehensive test profile that incorporates critical stress parameters, including supply voltage, input clock frequency, electrostatic discharge (ESD) sensitivity, and electrical endurance. Explicit criteria for stress selection, upper/lower bounds, step increments, and duration are established. A dedicated test platform is constructed, integrating automated test equipment (ATE) and ESD sensitivity analyzers with detailed specifications on device selection criteria and operational principles. The functional performance testing methodology is systematically investigated, covering test platform configuration, initialization protocols, parametric testing procedures, functional verification, and acceptance criteria. Extreme-condition experiments—including supply voltage margining, input clock frequency tolerance, ESD sensitivity characterization, and accelerated electrical endurance testing—are conducted to quantify operational and destructive limits. The findings provide critical theoretical insights and practical guidelines for the design optimization, quality control, and reliability enhancement of 3D-packaged memory devices. Full article

This study investigates the surface modification of Ti-6Al-4V alloy through the electrical discharge machining (EDM) process to improve its suitability for orthopedic and dental implant applications. The analysis focused on evaluating the morphological, wettability, roughness, hardness, and biocompatibility properties of the modified surfaces. Samples were subjected to different dielectric fluids and polarities during EDM. Subsequently, optical microscopy, roughness measurements, Vickers microhardness, contact angle tests, and in vitro cytotoxicity assays were performed. The results demonstrated that EDM processing led to the formation of distinct layers on the sample surfaces, with surface roughness increasing under negative polarity by up to ~304% in Ra and 305% in Rz. Additionally, wettability measurements indicated that the modified surfaces presented a lower water contact angle, which suggests enhanced hydrophilicity. Moreover, the modified samples showed a significant increase in Vickers microhardness, with the highest value reaching 1520 HV in the recast layer, indicating improvements in the mechanical properties. According to ISO 10993-5, all treated samples were classified as non-cytotoxic, presenting RGR values above 75%, similar to the untreated Ti-6Al-4V alloy. Therefore, it is concluded that surface modification through the EDM process has the potential to enhance the properties and safety of biomedical implants made with this alloy. Full article

Non-thermal plasma technology is used in the food sector due to its many advantages such as low operating costs, fast and efficient processing at low temperatures, minimal environmental impact, and preservation of sensory and nutritional properties. In this article, the plasma was generated using a high-voltage electrical discharge (HVED) with argon at a voltage of 35 kV and a frequency of 60 Hz. Plasma monitoring and diagnostics were performed using optical emission spectroscopy (OES) to optimise the process parameters and for quality control. OES was used as a non-invasive sensor to collect useful information about the properties of the plasma and to identify excited species. The values obtained for electron temperature and electron density (up to $2.3 \mathrm{eV}$ and up to ${10}^{23} {\mathrm{m}}^{-3}$) confirmed that the generated plasma is a non-thermal plasma. Therefore, the use of OES is recommended in the daily control of food processing, as this is necessary to confirm that the processes are non-thermal and suitable for the food sector. Full article

The charge structure and lightning activities during the development stage of a thunderstorm with a hail-falling process in Datong County of Qinghai Province on 16 August 2014 were studied by using a multi-station observation network composed of a very-high-frequency, three-dimensional, lightning-radiation-source location system and broadband electric field. The research results show that two discharge regions appeared during the development stage of the thunderstorm. The charge structure was all a negative dipolar polarity in two discharge regions; however, the heights of the charge regions were different. The positive-charge region at a height of 2–3.5 km corresponds to −1–−10 °C and the negative-charge region at a height of 3.5–5 km corresponds to −11–−21 °C in one discharge region; the positive-charge region at a height of 4–5 km corresponds to −15–−21 °C and the negative-charge region at a height of 5–6 km corresponds to −21–−29 °C in another region. The charge regions with the same polarity at different heights in the two discharge regions gradually connected with the occurrence of the hail-falling process during the development stage of the thunderstorm, and the overall height of the charge regions decreased. All the intracloud lightning flashes that occurred in the thunderstorm were of inverted polarity discharge, and the horizontal transmission distance of the discharge channel was short, all within 10 km. The negative intracloud lightning flash, negative cloud-to-ground lightning flash, and positive cloud-to-ground lightning flash generated during the thunderstorm process accounted for 83%, 16%, and 1% of the total number of lightning flashes, respectively. Negative cloud-to-ground lightning flashes mainly occurred more frequently in the early phase of the thunderstorm development stage. As the thunderstorm developed, the frequency of intracloud lightning flashes became greater than that of negative cloud-to-ground lightning flashes, and finally far exceeded it. The frequency of lightning flashes decreases sharply and the intensity of thunderstorms decreases during the hail-falling period. Full article