Search Results (29)

Miniature vapor compression refrigeration systems are gaining increasing relevance in cutting-edge applications such as drone docking station cooling, electric vehicle battery thermal management, portable medical and diagnostic devices, compact beverage dispensers, field-mounted telecom cabinet cooling, as well as the already established fields of electronics and personal cooling. These systems offer a promising pathway to localized and mobile cooling solutions. When coupled with the implementation of alternative low-GWP refrigerants that match or even enhance system performance, the result is a more efficient, environmentally responsible, and potentially sustainable refrigeration technology. Therefore, this study experimentally evaluates the performance of R515B as a low-GWP drop-in replacement for R134a in a miniature vapor compression refrigeration system. Key parameters were analyzed to determine the most suitable operating conditions, resulting in a capillary length of 1.25 m, refrigerant charge of 110 g, compressor speed of 4500 rpm, and high condenser fan speed, under which R515B achieved a COP of 5.16 and a cooling capacity of 252.20 W, representing improvements of 38% and 6.5%, respectively, compared to R134a. These results confirm the viability of R515B as an efficient, environmentally friendly alternative for miniature small-scale vapor compression systems. Full article

This paper presents the design and implementation of a low-cost microcontroller-based dual-channel fan controller optimized for high-power audio amplifiers, yet adaptable to power supplies, electronic loads, and other thermally intensive systems. Unlike conventional designs that drive all fans uniformly, the proposed solution provides fully independent cooling via dual I²C temperature sensors, predictive trend analysis, and multi-stage hysteresis. The controller incorporates advanced features including an anti-dust startup sequence, predictive boost with latching, active cross-cooling, anti-heat-soak protection, and stall detection via tachometer monitoring, complemented by LED-based fault signaling and automatic channel muting during overheating or fan failure. Hardware support for 12 V and 24 V fans, dual power-input options, and a compact PCB layout enhance integration flexibility. The firmware employs temperature-driven PWM mapping with EMA filtering and multi-level hysteresis. The experimental results confirm that all implemented features operate as intended, with each function demonstrating clear practical relevance, whether in improving responsiveness, preventing heat accumulation, or enhancing system reliability under a wide range of operating conditions. Full article

With advancements in simulation technology, fluid–thermal interaction (FTI) has become a vital tool in machinery powertrain development. Traditional engine cooling systems, with mechanically coupled components like water pumps and fans, lack adaptive cooling control. Electronic cooling systems, however, use variable-speed components to enhance performance. Combining FTI simulations with intelligent optimization algorithms offers a novel approach to designing control strategies for these systems. This study establishes a multi-objective optimization model for pump and fan speed control in electronic cooling systems. Using MATLAB/Simulink 2018 and Fluent 2022R1, co-simulations were performed, and an elite-strategy-based NSGA-II algorithm was implemented. Different weights were assigned to optimization objectives based on engine performance requirements. The results provide fitted functions for heat exchange capacity and cylinder liner temperature versus flow rates, along with optimal solutions for a 65 kW engine under three weight configurations. These findings support control strategy design and demonstrate the integration of FTI with genetic algorithms. Full article

Electromagnetic pumps are developed for industrial, medical and scientific applications, moving electrically conductive liquids and molten solder in electronics manufacturing using electromagnetism instead of mechanical parts. This study presents a comprehensive thermal analysis of an electromagnetic diaphragm pump, focusing on the influence of operating current, permanent magnet switching speed, and cooling conditions on pumping performance. The pump utilizes a flexible diaphragm embedded with a permanent neodymium magnet, which interacts with time-varying magnetic fields generated by electromagnets to drive fluid motion. Temperature monitoring is conducted using a waterproof DS18B20 sensor and an uncooled FLIR A325sc infrared camera, allowing accurate mapping of thermal distribution across the pump surface. Experimental results demonstrate that higher current and increased magnet switching speed lead to faster temperature rise, impacting the volume of fluid pumped. Incorporation of an automatic cooling fan effectively reduces coil temperature and stabilizes pump performance. Polynomial regression models describe the relationship between temperature, pumped liquid volume, and magnet switching speed, providing information to optimize pump operation and cooling strategies. The novel relationship between temperature and the volume of the pumped liquid is considered as a fourth-degree polynomial. In particular the model describes a quantitative evaluation of the effect of heating on pumping efficiency. An initial increase in temperature correlates with a higher pumped volume, but excessive heating leads to efficiency saturation or even decline. Indeed, mathematical dependencies are crucial in mechanical pump engineering for analyzing physical phenomena; this is achieved by using a mathematical equation to define how different physical variables are related to each other, enabling engineers to calculate performance and optimize the pump design. Full article

Micro gas turbines serve small-scale generation where swift response and low emissions are highly valued, and they are commonly fuelled by natural gas. True to their ‘micro’ designation, their size is indeed compact; however, a noteworthy portion of the enclosure is devoted to power electronics components. This article considers whether these components can be made even smaller by substituting their conventional silicon switches with switches fashioned from silicon carbide. The wider bandgap of silicon carbide permits stronger electric fields and reliable operation at higher temperatures, which together promise lower switching losses, less heat, and simpler cooling arrangements. This study rests on a simple volumetric model. Two data sets feed the model. First come the manufacturer specifications for a pair of converter modules (one silicon, the other silicon carbide) with identical operation ratings. Second are the operating data and dimensions of a commercial 100 kW micro gas turbine. The model splits the converter into two parts: the semiconductor package and its cooling hardware. It then applies scaling factors that capture the higher density of silicon carbide and its lower switching losses. Lower switching losses reduce generated heat, so heatsinks, fans, or coolant channels can be slimmer. Together these effects shrink the cooling section and, therefore, the entire converter. The findings show that a micro gas turbine inverter built with silicon carbide occupies about one fifth less space and delivers more than a quarter higher power density than its silicon counterpart. Full article

The increasing demand for induction hobs necessitates efficient cooling systems to ensure the safe operation of electronic cut-outs. This study investigates the thermal representation of three different ignition designs integrated into an induction hob cooling system. A simplified model consisting of a radial fan, a daughterboard, and the electronics installed in the systems is used for the maintenance of the system. Remote measurements of air velocities at the cooler outlets are compared with the results obtained through programmable system dynamics (CFD) operations using FloEFD v2021.1 software. The findings of the study using the k-ε turbulence model show that Type 1 temperature is resistant to the lowest surface temperature for both the closest (IGBT 1) and the farthest (IGBT 2) temperature to the fan. Conversely, Type 3 temperatures exhibited high temperatures. Air velocity comparisons showed a maximum error rate of 30%, which is acceptable considering the variability in Type 1. Measurement system evaluation and DOE study were continued to increase the experimental range. This study demonstrates the utility offered by heatsink design in optimizing the cooling system of induction hobs and provides valuable insights for integrating thermal management systems. Full article

Due to accelerated urbanization, modern urban residents are facing increasing life pressures. Many citizens are experiencing situational aversion in daily commuting, and the deterioration in the traffic environment has led to psychological distress of varying degrees among urban dwellers. Cyclists, who account for about 7% of urban commuters, lack a sense of belonging in the urban space and experience significant deficiencies in the corresponding urban infrastructure, which causes more people to face significant barriers to choosing cycling as a mode of transportation. To address the aforementioned issues, this study proposes a bionic intelligent interaction helmet (BIIH) designed and validated based on the principles of bionics, which has undergone morphological design and structural validation. Constructed around the STM32-embedded development board, the BIIH is an integrated smart cycling helmet engineered to perceive environmental conditions and enable both human–machine interactions and environment–machine interactions. The system incorporates an array of sophisticated electronic components, including temperature and humidity sensors; ultrasonic sensors; ambient light sensors; voice recognition modules; cooling fans; LED indicators; and OLED displays. Additionally, the device is equipped with a mobile power supply, enhancing its portability and ensuring operational efficacy under dynamic conditions. Compared with conventional helmets designed for analogous purposes, the BIIH offers four distinct advantages. Firstly, it enhances the wearer’s environmental perception, thereby improving safety during operation. Secondly, it incorporates a real-time interaction function that optimizes the cycling experience while mitigating psychological stress. Thirdly, validated through bionic design principles, the BIIH exhibits increased specific stiffness, enhancing its structural integrity. Finally, the device’s integrated power and storage capabilities render it portable, autonomous, and adaptable, facilitating iterative improvements and fostering self-sustained development. Collectively, these features establish the BIIH as a methodological and technical foundation for exploring novel research scenarios and prospective applications. Full article

Temperature is a crucial parameter for ensuring the long lifespan and safe operation of lithium-ion batteries (LiBs). An efficient battery thermal management system (BTMS) tries to maintain temperature in between optimum limits. Despite some disadvantages, air-cooled BTMSs are still preferred due to their advantages such as light weight, simple design, low cost, and ease of maintenance. This study experimentally evaluated a fan-assisted BTMS for the purpose of cooling a 4S2P battery module that includes 18650 type cells. The battery module was initially tested with no cooling system to observe the temperature characteristics of the module, followed by testing with forced air cooling using a fan. Experiments were also conducted with perforated plates installed between the fan and the module to see their effects on the thermal behaviors. Tests were initiated when the ambient temperature was approximately 25 °C and the discharges were carried out by drawing constant currents of 4 A, 8 A, 12 A, and 16 A from the module via an electronic load. The results of this study highlighted the importance of an effective BTMS in ensuring battery safety and performance across different operational conditions. While all tested cooling configurations maintained acceptable temperature levels at lower discharge currents (4 A and 8 A), they struggled to do so at higher currents (12 A and 16 A). Among them, the Fan–HC mode demonstrated the highest efficiency, reducing the maximum temperature (T_max) by 38.82% at 12 A and 28.89% at 16 A compared to the no-cooling scenario. Moreover, it ensured a more uniform temperature distribution within the module. These findings emphasize the necessity of optimized cooling strategies, particularly for high-power applications. Full article

The onboard circuits of EV chargers comprise heat-producing electronic devices such as MOSFETs and diodes for switching and power conversion operations. A heatsink must dissipate this generated heat to extend the devices’ life and prevent component thermal stress or failure. This study primarily investigates the optimal heatsink geometry and pin configuration, which offers the most efficient temperature versus cost performance. MATLAB/Simulink (R2024a) was used to model a Level 1 charger using eight MOSFETs and four diodes. Various heatsink geometries were modeled using the ANSYS (2024 R1) Workbench and Fluent software to optimize the sink’s thermal performance. The analyses were performed under transient conditions using natural and forced cooling scenarios. The 2 mm wide plate fin heatsink with 44 fins yielded the best result. Further enhancement of the best-performing naturally cooled model improved the switches and diodes temperatures by 14% and 4%, respectively. The performance of the heatsink was further improved by applying a cooling fan to achieve an up to 25% diode and 40% MOSFET thermal dissipation efficiency. The results of this study show that the most efficient cooling performance and cost are realized when the optimum combination of fin spacing, proximity from the cooling fan, and fin geometry is selected. Full article

In the rapidly advancing field of 5G technology, efficient thermal management is essential for enhancing the performance and reliability of high-power-density integrated circuits (ICs). This paper introduces an innovative approach to cooling these critical components, significantly surpassing traditional methods. Our design optimizes heatsink and fan configurations through systematic experimentation, varying fin shapes, heatsink dimensions, and fan speeds. The results demonstrate that fan velocity is the most critical factor in reducing IC temperatures, as increased airflow dramatically lowers thermal output. Expanding the heatsink surface area further improves heat dissipation by enhancing airflow interaction, while a larger copper heatsink boosts thermal conduction, effectively reducing the final IC temperature. These optimizations streamline the cooling process, minimizing the need for more complex and expensive equipment. This research sets a new benchmark in thermal management, fostering the development of more efficient and reliable electronic systems in the era of advanced wireless communications. Our approach brings a new dimension to existing research by focusing on the optimization of heatsink and airflow designs specifically for ICs. While previous studies have explored broader thermal management strategies, our work addresses specific challenges in heat dissipation by refining geometric configurations and fan speed adjustments. These optimizations result in measurable improvements in both efficiency and scalability, particularly within the context of high-power 5G systems. Full article

The growth of electrical machine applications in high-torque environments such as marine propulsion and wind energy is encouraging the development of higher-power-density machines at ever higher efficiencies and under competitive pressure to meet higher demands. In this study, numerical simulations are performed to investigate the characteristics of air cooling applied to a 3 MW high-torque internal permanent magnet electric machine with integrated power electronics. The whole system of the main machine and two converters at either end are modelled with all details. Effects of different parameters on the total pressure drop and air flow rate to the machine and converters are examined. Results show that by changing the converter outlet hole size, the air flow rate to the machine and converter can be adjusted. Air guides and pin vents reveal excellent performance in the distribution of air to laminations and windings with a penalty of some increase in pressure drop, which is more pronounced when using smaller outlet holes. Furthermore, the air return manifold increases the pressure drop and causes a reduction in air flow rate to the converter. Insulation between compression plate and laminations is an unavoidable component used in electric machines and acts as a thermal insulator. However, it can also significantly augment pressure drop, especially in combination with smaller outlet holes. Thermal studies of the integrated power electronics illustrate that components’ temperatures are less than the temperature limit, confirming enough air through the converter. Analysis of power electronics in the case of fan failure provides the operational time window for the operators to respond. Full article

In this study the flow field of a centrifugal electronic cooling fan operating at an off-design point of 0 Pa static fan pressure is investigated by means of Computational Fluid Dynamics. The results obtained by four different turbulence models, the realizable k-$ϵ$ model, the SST k-$\omega$ model, a Reynolds Stress Model, and Scale-Adaptive Simulation are analyzed and compared. The focus lies on describing how the flow through impeller and volute influences the fan outlet flow field, and velocity profiles and velocity fluctuations at the outlet are compared to previously published measurements. All models tend to underpredict the measured outlet flow rate, but are capable of producing the characteristic C-shaped profile of high velocities, previously determined in Constant Temperature Anemometry measurements. However, the realizable k-$ϵ$ model is significantly too diffusive, leading to blurred velocity contours. The other models exhibit reasonable agreement with the measured flow field, but show differences in a number of aspects. The SST k-$\omega$ model, for instance, even produces local inflow in a confined area. The SAS approach overpredicts the length of the lower lobe of the C-shape. The research is relevant to improve simulation results of impingement cooling and heat sink optimization using centrifugal fans. Full article

As an alternative to conventional mechanical fans, EHD fans and/or EHD gas pumps, which generate less noise, were investigated for cooling systems, such as in electronic equipment and automobiles. Wire-parallel plate electrode type EHD fans, which have greater design freedom and potential for practical application, have been suggested. This study clarifies the characteristics of a wire-partially insulated parallel plate electrode type EHD fan under DC positive applied voltage. In order to understand the characteristics of the EHD fan more deeply, visualizations of the air flow in the flow channel and the exit area were conducted by using PIV and CFD analyses. In the experiment, air at atmospheric pressure and room temperature was used as a working fluid. The experimental results for fan characteristics of the EHD fan, such as the velocity profile, cross-sectional average velocity, volumetric flow rate in the flow channel or at the exit area, power, and so on, are considered in detail. In addition, the flow visualization and the instantaneous and time-averaged velocity profiles from the PIV analysis are discussed. A comparison with the experimental results described above, and differences of flow regime for different locations, are also presented and discussed. Furthermore, a two-dimensional steady state flow simulation by means of CFD analysis was conducted and its experimental results analyzed. Full article

The current paper aims to present a cooling concept for future centralized platforms of ECUs (Electronic Control Units) from the automotive industry that involves grouping multiple electronic devices into a single system and cooling them with forced convection dielectric coolant. The enhancement consists of replacing the inside air of the module with a dielectric coolant that has a higher thermal conductivity than air and employing an additional prototype system that aids in forced liquid cooling. To meet automotive requirements, the experiments were exposed to an ambient temperature of 85 °C. Temperature measurements on these solutions’ hot spots were compared to those on a thermal paste-only reference electronic module. This study used DFSS (Design for Six Sigma) techniques to determine the ideal pump flow rate, fan air flow rate, and liquid volume in the housing, leading to an optimization in heat dissipation. Finding a trustworthy transfer function that could forecast the impact of the crucial design parameters that had been found was the main goal. The electronics cooled by forced convection coolant improved heat dissipation by up to 60% when compared to the reference module. This demonstrates that the DoE (Design of Experiments) method, which is based on a limited number of measurements, can estimate the behavior of the ECU without the need for a more involved theoretical framework. Full article

Telecommunication systems have become a critical part of society which enables connectivity to many essential and trivial services. Consequently, telecommunication equipment is housed in cabinets to protect the electronics from a variety of hazards; one of which is temperature-related failure. Current practices use a notable amount of power for the thermal management of telecommunication cabinets which can be reduced by considering alternative methods of cooling. In this paper, experiments were carried out to investigate the effectiveness of different internal mounting configurations of electronic components on the thermal performance of a telecommunication cabinet. The investigation tested inclinations (0–90°), different staggered offsets (0–50 mm), changing stream-wise spacing (29–108 mm), and fan speed (with a Reynolds number in the range of 1604 to 5539). The experimental study revealed that heat transfer was enhanced by $9.99\%$ by altering component inclination to 90°, 25.90% by increasing stream-wise spacing from 29 mm to 108 mm, and 36.02% by increasing the Reynolds number from 1604 to 5539. However, the staggered arrangement of internal components decreased $Nu$ by 3.26% for the natural convection condition but increased by 5.69% for the forced convection condition over the tested range and increasing the centre offset of the staggered components with respect to the cabinet did not influence $Nu$ in any significant manner. Natural convection and forced convection also had notable influence on the heat transfer rate. Hence it was seen that alternative internal configurations positively influence heat transfer in telecommunication cabinets for the cases studied. Full article