Search Results (1,371)

Accurate State of Charge (SOC) estimation for retired power batteries remains a critical challenge due to their degraded electrochemical properties and heterogeneous aging mechanisms. Traditional methods relying solely on electrical parameters (e.g., voltage and current) exhibit significant errors, as aged batteries experience altered internal resistance, capacity fade, and uneven heat generation, which distort the relationship between electrical signals and actual SOC. To address these limitations, this study proposes a surface temperature-assisted SOC estimation method, leveraging the distinct thermal characteristics of retired batteries. By employing infrared thermal imaging, key temperature feature regions—the positive/negative tabs and central area—are identified, which exhibit strong correlations with SOC dynamics under varying operational conditions. A Gated Recurrent Unit (GRU) neural network is developed to integrate multi-region temperature data with electrical parameters, capturing spatial–temporal thermal–electrical interactions unique to retired batteries. The model is trained and validated using experimental data collected under constant current discharge conditions, demonstrating superior accuracy compared to conventional methods. Specifically, our method achieves 64.3–68.1% lower RMSE than traditional electrical-parameter-only approaches (V-I inputs) across 0.5 C–2 C discharge rates. Results show that the proposed method reduces SOC estimation errors compared to traditional voltage-based models, achieving RMSE values below 1.04 across all tested rates. This improvement stems from the model’s ability to decode localized heating patterns and their hysteresis effects, which are particularly pronounced in aged batteries. The method’s robustness under high-rate operations highlights its potential for enhancing the reliability of retired battery management systems in secondary applications such as energy storage. Full article

Under the background of “dual-carbon” strategy and global energy transition, the metallurgical industry, which accounts for 15–20% of industrial energy consumption, urgently needs to reduce the energy consumption and emission of DC power supply of electric furnaces. Aiming at the existing 400–800 V/≥3000 A industrial-frequency transformer-rectifier system with low efficiency, large volume, heat dissipation difficulties and other bottlenecks, this thesis proposes and realizes a high-frequency integrated DC power supply scheme for high-power electric furnaces: high-frequency transformer core and rectifier circuit are deeply integrated, which breaks through and reduces the volume of the system by more than 40%, and significantly reduces the iron consumption; multiple cores and three windings in parallel are used for the system. The topology of multiple cores and three windings in parallel enables several independent secondary stages to share the large current of 3000 A level uniformly, eliminating the local overheating and current imbalance; the combination of high-frequency rectification and phase-shift control strategy enhances the input power factor to more than 0.95 and cuts down the grid-side harmonics remarkably. The authors have completed the design of 100 kW prototype, magneto-electric joint simulation, thermal structure coupling analysis, control algorithm development and field comparison test, and the results show that the program compared with the traditional industrial-frequency system efficiency increased by 12–15%, the system temperature rise reduced by 20 K, electrode voltage increased by 10–15%, the input power of furnace increased by 12%, and the harmonic index meets the requirements of the traditional industrial-frequency system. The results show that the efficiency of this scheme is 12–15% higher than the traditional IF system, the temperature rise in the system is 20 K lower, the voltage at the electrode end is 10–15% higher, the input power of the furnace is increased by 12%, and the harmonic indexes meet the requirements of GB/T 14549, which verifies the value of the scheme for realizing high efficiency, miniaturization, and reliable DC power supply in metallurgy. 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 study proposes the SMR Smart Net-Zero City (SSNC) framework—a scalable model for achieving carbon neutrality by integrating Small Modular Reactors (SMRs), renewable energy sources, and sector coupling within a microgrid architecture. As deploying renewables alone would require economically and technically impractical energy storage systems, SMRs provide a reliable and flexible baseload power source. Sector coupling systems—such as hydrogen production and heat generation—enhance grid stability by absorbing surplus energy and supporting the decarbonization of non-electric sectors. The core contribution of this study lies in its real-time data emulation framework, which overcomes a critical limitation in the current energy landscape: the absence of operational data for future technologies such as SMRs and their coupled hydrogen production systems. As these technologies are still in the pre-commercial stage, direct physical integration and validation are not yet feasible. To address this, the researchers leveraged real-time data from an existing commercial microgrid, specifically focusing on the import of grid electricity during energy shortfalls and export during solar surpluses. These patterns were repurposed to simulate the real-time operational behavior of future SMRs (ProxySMR) and sector coupling loads. This physically grounded simulation approach enables high-fidelity approximation of unavailable technologies and introduces a novel methodology to characterize their dynamic response within operational contexts. A key element of the SSNC control logic is a day–night strategy: maximum SMR output and minimal hydrogen production at night, and minimal SMR output with maximum hydrogen production during the day—balancing supply and demand while maintaining high SMR utilization for economic efficiency. The SSNC testbed was validated through a seven-day continuous operation in Busan, demonstrating stable performance and approximately 75% SMR utilization, thereby supporting the feasibility of this proxy-based method. Importantly, to the best of our knowledge, this study represents the first publicly reported attempt to emulate the real-time dynamics of a net-zero city concept based on not-yet-commercial SMRs and sector coupling systems using live operational data. This simulation-based framework offers a forward-looking, data-driven pathway to inform the development and control of next-generation carbon-neutral energy systems. Full article

This study systematically investigates 50 μm-diameter 631 stainless steel fine wires subjected to both sequential and simultaneous electrothermomechanical loading to simulate probe spring conditions in microelectronic test environments. Under cyclic current loading (~10⁴ A/cm²), the 50 μm 631SS wire maintained electrical integrity up to 0.30 A for 15,000 cycles. Above 0.35 A, rapid oxide growth and abnormal grain coarsening resulted in surface embrittlement and mechanical degradation. Current-assisted tensile testing revealed a transition from recovery-dominated behavior at ≤0.20 A to significant thermal softening and ductility loss at ≥0.25 A, corresponding to a threshold temperature of approximately 200 °C. These results establish the endurance limit of 631 stainless steel wire under coupled thermal–mechanical–electrical stress and clarify the roles of Joule heating, oxidation, and microstructural evolution in electrical fatigue resistance. A degradation map is proposed to inform design margins and operational constraints for fatigue-tolerant, electrically stable interconnects in high-reliability probe spring applications. Full article

This study presents a comparative analysis of the annual performances of stationary and dual-axis sun-tracked photovoltaic–thermal (PVT) systems. The experimental research was conducted at a demonstration site in Oświęcim, Poland, where both systems were evaluated in terms of electricity and heat production. The test installation consisted of thirty stationary PVT modules and five dual-axis sun-tracking systems, each equipped with six PV modules. An innovative cooling system was developed for the PVT modules, consisting of a surface-mounted heat sink installed on the rear side of each panel. The system includes embedded tubes through which a cooling fluid circulates, enabling efficient heat recovery. The results indicated that the stationary PVT system outperformed a conventional fixed PV installation, whose expected output was estimated using PVGIS data. Specifically, the stationary PVT system generated 26.1 kWh/m² more electricity annually, representing a 14.8% increase. The sun-tracked PVT modules yielded even higher gains, producing 42% more electricity than the stationary system, with particularly notable improvements during the autumn and winter seasons. After accounting for the electricity consumed by the tracking mechanisms, the sun-tracked PVT system still delivered a 34% higher net electricity output. Moreover, it enhanced the thermal energy output by 85%. The findings contribute to the ongoing development of high-performance PVT systems and provide valuable insights for their optimal deployment in various climatic conditions, supporting the broader integration of renewable energy technologies in building energy systems. Full article

Surface Air-Cooled Oil Coolers (SACOCs) can become a critical component in managing the increasing thermal loads of modern turbofan engines. Installed within the bypass duct, SACOCs utilize high-mass flow bypass air for convective heat rejection, reducing reliance on traditional Fuel-Oil Heat Exchangers. This review explores SACOC design principles, integration challenges, aerodynamic impacts, and performance trade-offs. Emphasis is placed on the balance between thermal efficiency and aerodynamic penalties such as pressure drop and flow distortion. Experimental techniques, including wind tunnel testing, are discussed alongside numerical methods, and Conjugate Heat Transfer modeling. Presented studies mostly demonstrate the impact of fin geometry and placement on both heat transfer and drag. Optimization strategies and Additive Manufacturing techniques are also covered. SACOCs are positioned to play a central role in future propulsion systems, especially in ultra-high bypass ratio and hybrid-electric architectures, where traditional cooling strategies are insufficient. This review highlights current advancements, identifies limitations, and outlines research directions to enhance SACOC efficiency in aerospace applications. Full article

Reducing gear noise in electric vehicle (EV) drivetrains is crucial due to the absence of internal combustion engine noise, making even minor acoustic disturbances noticeable. Manufacturing parameters significantly influence gear-generated noise, yet traditional analytical methods often fail to predict these complex relationships accurately. This research addresses this gap by introducing a data-driven approach using machine learning (ML) to predict gear noise levels from manufacturing and sensor-derived data. The presented methodology encompasses systematic data collection from various production stages—including soft and hard machining, heat treatment, honing, rolling tests, and end-of-line (EOL) acoustic measurements. Predictive models employing Random Forest, Gradient Boosting (XGBoost), and Neural Network algorithms were developed and compared to traditional statistical approaches. The analysis identified critical manufacturing parameters, such as surface waviness, profile errors, and tooth geometry deviations, significantly influencing noise generation. Advanced ML models, specifically Random Forest, XGBoost, and deep neural networks, demonstrated superior prediction accuracy, providing early-stage identification of gear units likely to exceed acceptable noise thresholds. Integrating these data-driven models into manufacturing processes enables early detection of potential noise issues, reduces quality assurance costs, and supports sustainable manufacturing by minimizing prototype production and resource consumption. This research enhances the understanding of gear noise formation and offers practical solutions for real-time quality assurance. Full article

The design of aircraft electrical wiring interconnection systems (EWISs) is central to ensuring the safe and reliable operation of aircraft. The calculation of the temperature rise characteristics of aircraft wire harnesses is one of the key technologies in EWIS design, directly affecting the safety margin of the system. However, existing calculation methods generally face a bottleneck in the balance between speed and accuracy, failing to meet the requirements of actual engineering applications. In this paper, we conduct an in-depth study on this issue. Firstly, a finite element harness model is established to accurately obtain the convective heat transfer coefficients of wires and harnesses. Based on the analysis of the influencing factors of the thermal network model for a single wire, an improved thermal resistance hierarchical wire thermal network model is proposed. A structure consisting of series thermal resistance within layers and iterative parallel algorithms between layers is proposed to equivalently integrate and iteratively calculate the mutual thermal influence relationship between each layer of the harness, thereby constructing a hierarchical harness thermal network model. This model successfully achieves a significant improvement in calculation speed while effectively ensuring useable temperature rise results, providing an effective method for EWIS design. Full article

This study presents a comprehensive case of green remodeling applied to a local fire station in Seoul, South Korea. The project aimed to improve energy performance through an integrated upgrade of passive systems (exterior insulation, high-performance windows, and airtightness) and active systems (electric heat pumps, energy recovery ventilation, and rooftop photovoltaic systems), while maintaining uninterrupted emergency operations. A detailed analysis of annual energy use before and after the remodeling shows a 44% reduction in total energy consumption, significantly exceeding the initial reduction target of 20%. While electricity use increased modestly during winter due to the electrification of heating systems, gas consumption dropped sharply by 63%, indicating a shift in energy source and improved efficiency. The building’s airtightness also improved significantly, with a reduction in the air change rate. The project further addressed unique challenges associated with continuously operated public facilities, such as insulating the fire apparatus garage and executing phased construction to avoid operational disruption. This study contributes valuable insights into green remodeling strategies for mission-critical public buildings, emphasizing the importance of integrating technical upgrades with operational constraints to achieve verified energy performance improvements. Full article

Improving the energy efficiency of residential buildings is essential for achieving global climate goals and reducing environmental impact. This study analyzes the Total Performance approach using the example of a modern semi-detached house built by a Polish developer, as an example. The building is designed with integrated systems that minimize energy consumption while maintaining resident comfort. The building is equipped with an air-to-water heat pump, underfloor heating, mechanical ventilation with heat recovery, and automatic temperature control systems. Energy efficiency was assessed using ArCADia–TERMOCAD 8.0 software in accordance with Polish Technical Specifications (TS) and verified by monitoring real-time electricity consumption during the heating season. The results show a PED from non-renewable sources of 54.05 kWh/(m²·year), representing a 23% reduction compared to the Polish regulatory limit of 70 kWh/(m²·year). Real-time monitoring conducted from December 2024 to April 2025 confirmed these results, indicating an actual energy demand of approximately 1771 kWh/year. Domestic hot water (DHW) preparation accounted for the largest share of energy consumption. Despite its dependence on grid electricity, the building has the infrastructure to enable future photovoltaic (PV) installation, offering further potential for emissions reduction. The results confirm that Total Performance strategies are not only compliant with applicable standards, but also economically and environmentally viable. They represent a scalable model for sustainable residential construction, in line with the European Union’s (EU’s) decarbonization policy and the goals of the European Green Deal. Full article

The ongoing rise in global electricity demand highlights the need for advanced, efficient, and environmentally responsible energy conversion technologies. This research presents a comprehensive design, modeling, and experimental validation of a tubular permanent magnet linear alternator (PMLA) integrated with a free piston engine system. Linear alternators offer a direct conversion of linear motion to electricity, eliminating the complexity and losses associated with rotary generators and enabling higher efficiency and simplified system architecture. The study combines analytical modeling, finite element simulations, and a sensitivity-based design optimization to guide alternator and engine integration. Two prototype systems, designated as alpha and beta, were developed, modeled, and tested. The beta prototype achieved a maximum electrical output of 550 W at 57% efficiency using natural gas fuel, demonstrating reliable performance at elevated reciprocating frequencies. The design and optimization of specialized flexure springs were essential in achieving stable, high-frequency operation and improved power density. These results validate the effectiveness of the proposed design approach and highlight the scalability and adaptability of PMLA technology for sustainable power generation. Ultimately, this study demonstrates the potential of free piston linear generator systems as efficient, robust, and environmentally friendly alternatives to traditional rotary generators, with applications spanning hybrid electric vehicles, distributed energy systems, and combined heat and power. Full article

Electric submersible pumps (ESPs) are critical for artificial lift operations; however, they are prone to frequent failures, often resulting in high operational costs and production downtime. Traditional ESP failure classifications are limited by lack of standardization and the conflation of failure modes with root causes. To address these limitations, this study proposes a new two-step integrated failure modes and root cause (IFMRC) classification system. The new framework clearly distinguishes between failure modes and root causes, providing a systematic, structured approach that enhances fault diagnosis and failure analysis and can lead to better failure prevention strategies. This methodology was validated using a case study of over 4000 ESP installations. The data came from Egypt’s Western Desert, covering a decade of operational data. The sources included ESP databases, workover records, and detailed failure investigation (DIFA) reports. The failure modes were categorized into electrical, mechanical, hydraulic, chemical, and operational types, while root causes were linked to environmental, design, operational, and equipment factors. Statistical analysis, in this case study, revealed that motor short circuits, low flow conditions, and cable short circuits were the most frequent failure modes, with excessive heat, scale deposition, and electrical grounding faults being the dominant root causes. This study underscores the importance of accurate root cause failure classification, robust data acquisition, and expanded failure diagnostics to improve ESP reliability. The proposed IFMRC framework addresses limitations in conventional taxonomies and facilitates ongoing enhancement of ESP design, operation, and maintenance in complex field conditions. Full article

A novel approach to managing domestic heating systems through IoT technologies is introduced in this paper. The system optimizes energy consumption by dynamically adapting to electricity and fuel price fluctuations while maintaining user comfort. Integrating smart devices significantly reduce energy costs and offer a favorable payback period, positioning the solution as both sustainable and economically viable. Efficient heating management is increasingly critical amid growing energy and environmental concerns. This strategy uses IoT devices to collect real-time data on prices, consumption, and user preferences. Based on this data, the system adjusts heating settings intelligently to balance comfort and cost savings. IoT connectivity manages continuous monitoring and dynamic optimization in response to changing conditions. This study includes a real-case comparison between a conventional central heating system and an IoT-managed electric radiator setup. By applying automation rules linked to energy pricing and user habits, the system enhances energy efficiency, especially in cold climates. The economic evaluation shows that using low-cost IoT devices yields meaningful savings and achieves equipment payback within approximately three years. The results demonstrate the system’s effectiveness, demonstrating that smart, adaptive heating solutions can cut energy expenses without sacrificing comfort, while offering environmental and financial benefits. Full article

Gasification of municipal solid waste and other biogenic residues (e.g., biomass and biowaste) is increasingly recognized as a promising thermochemical pathway for converting non-recyclable fractions into valuable energy carriers, with applications in electricity generation, district heating, hydrogen production, and synthetic fuels. This paper provides a comprehensive analysis of major gasification technologies, including fixed bed, fluidized bed, entrained flow, plasma, supercritical water, microwave-assisted, high-temperature steam, and rotary kiln systems. Key aspects such as feedstock compatibility, operating parameters, technology readiness level, and integration within circular economy frameworks are critically evaluated. A comparative assessment of incineration and pyrolysis highlights the environmental and energetic advantages of gasification. The valorization pathways for main product (syngas) and by-products (syngas, ash, tar, and biochar) are also explored, emphasizing their reuse in environmental, agricultural, and industrial applications. Despite progress, large-scale adoption in Europe is constrained by economic, legislative, and technical barriers. Future research should prioritize scaling emerging systems, optimizing by-product recovery, and improving integration with carbon capture and circular energy infrastructures. Supported by recent European policy frameworks, gasification is positioned to play a key role in sustainable waste-to-energy strategies, biomass valorization, and the transition to a low-emission economy. Full article