Search Results (274)

Accurate parametric modeling of lithium-ion batteries is essential for battery management system (BMS) design in electric vehicles and broader energy storage applications, enabling reliable state estimation and effective thermal control under diverse operating conditions. This study presents a detailed characterization of lithium-ion cells to support advanced BMS in electric vehicles and stationary storage. A second-order equivalent circuit model is developed to capture instantaneous and dynamic voltage behavior, with parameters extracted through Hybrid Pulse Power Characterization over a broad range of temperatures (−10 °C to 45 °C) and state-of-charge levels. The method includes multi-duration pulse testing and separates ohmic and transient responses using two resistor–capacitor branches, with parameters tied to physical processes like charge transfer and diffusion. A weakly coupled electro-thermal model is presented to support real-time BMS applications, enabling accurate voltage, temperature, and heat generation prediction. This study also evaluates open-circuit voltage and direct current internal resistance across pulse durations, leading to power capability maps (“fish charts”) that capture discharge and regenerative performance across SOC and temperature. The analysis highlights performance asymmetries between charging and discharging and confirms model accuracy through curve fitting across test conditions. These contributions enhance model realism, thermal control, and power estimation for real-world lithium-ion battery applications. Full article

Due to their advantages, such as abundant raw material reserves, excellent thermal stability, and superior low-temperature performance, sodium-ion batteries (SIBs) exhibit significant potential for future applications in energy storage and electric vehicles. Therefore, in this study, a commercial pouch-type SIB with sodium iron sulfate cathode material was investigated. Firstly, a second-order RC equivalent circuit model was established through parameter identification using multi-rate hybrid pulse power characterization (M-HPPC) tests at various temperatures. Then, both the specific heat capacity and entropy coefficient of the sodium-ion battery were measured through experiments. Building upon this, an electro-thermal coupling model was developed by incorporating a lumped-parameter thermal model that accounts for the heat generation of the tabs. Finally, the prediction performance of this model was validated through discharge tests under different temperature conditions. The results demonstrate that the proposed electro-thermal coupling model can achieve the simultaneous prediction of both temperature and voltage, providing valuable references for the future development of thermal management systems for SIBs. Full article

Internal conductive defects in composite insulators severely degrade their insulation performance and are considered concealed defects, posing a significant threat to the safe and stable operation of the power grid. Focusing on this issue, this study develops an electro-thermal multi-physical field simulation model and uses finite element analysis to investigate the electric field distribution and temperature rise characteristics. Composite insulator specimens with varying defect lengths were fabricated using the electrical erosion test. Charged tests were then conducted on these defective specimens, as well as on field-decommissioned specimens. The impact of internal conductive defects on the infrared, ultraviolet, and electric field distribution characteristics of composite insulators during operation was analyzed. The results indicate that the surface electric field of composite insulators with internal conductive defects becomes highly concentrated along the defect path, with a significant increase in electric field strength at the defect’s end. The maximum field strength migrates toward the grounded end as the defect length increases. Conductive defects lead to partial discharge and abnormal temperature rise at the defect’s end and the bending points of the composite insulator. The temperature rise predominantly manifests as “bar-form temperature rise,” with temperature rise regions correlating well with discharge areas. Conductive defects accelerate the decay-like degradation process of composite insulators through a positive feedback loop formed by the coupling of electric field distortion, Joule heating, material degradation, and discharge activity. This study identifies the key characteristics of electrical and temperature rise changes in insulators with conductive defects, reveals the deterioration evolution process and degradation mechanisms of insulators, and provides effective criteria for on-site diagnosis of conductive defects. Full article

Icing represents a significant hazard to the flight safety of unmanned aerial vehicles (UAVs), particularly affecting critical aerodynamic surfaces such as air intakes, wings, and empennages. While conventional adhesive electrothermal de-icing systems are straightforward to operate, they present safety concerns, including a 15–25% increase in system weight, elevated anti-/de-icing power consumption, and the risk of interlayer interface delamination. To address the objectives of reducing weight and power consumption, this study introduces an innovative electrothermal–structural–durability co-design strategy. This approach successfully led to the development of a glass fiber-reinforced polymer (GFRP) component that integrates anti-icing functionality with structural load-bearing capacity, achieved through an embedded hot-pressing process. A stress-damage cohesive zone model was utilized to accurately quantify the threshold of mechanical performance degradation under electrothermal cycling conditions, elucidating the evolution of interfacial stress and the mechanism underlying interlayer failure. Experimental data indicate that this novel component significantly enhances heating performance compared to traditional designs. Specifically, the heating rate increased by approximately 202%, electrothermal efficiency improved by about 13.8% at −30 °C, and interlayer shear strength was enhanced by approximately 30.5%. This research offers essential technical support for the structural optimization, strength assessment, and service life prediction of UAV anti-icing and de-icing systems in the aerospace field. Full article

Silicon carbide (SiC) half-bridge power modules are widely utilized in new energy power generation, electric vehicles, and industrial power supplies. To address the research gap in collaborative validation between electro-thermal coupling models and process reliability, this paper proposes a closed-loop methodology of “design-simulation-process-validation”. This approach integrates in-depth electro-thermal simulation (LTspice XVII/COMSOL Multiphysics 6.3) with micro/nano-packaging processes (sintering/bonding). Firstly, a multifunctional double-pulse test board was designed for the dynamic characterization of SiC devices. LTspice simulations revealed the switching characteristics under an 800 V operating condition. Subsequently, a thermal simulation model was constructed in COMSOL to quantify the module junction temperature gradient (25 °C → 80 °C). Key process parameters affecting reliability were then quantified, including conductive adhesive sintering (S820-F680, 39.3 W/m·K), high-temperature baking at 175 °C, and aluminum wire bonding (15 mil wire diameter and 500 mW ultrasonic power/500 g bonding force). Finally, a double-pulse dynamic test platform was established to capture switching transient characteristics. Experimental results demonstrated the following: (1) The packaged module successfully passed the 800 V high-voltage validation. Measured drain current (4.62 A) exhibited an error of <0.65% compared to the simulated value (4.65 A). (2) The simulated junction temperature (80 °C) was significantly below the safety threshold (175 °C). (3) Microscopic examination using a Leica IVesta 3 microscope (55× magnification) confirmed the absence of voids at the sintering and bonding interfaces. (4) Frequency-dependent dynamic characterization revealed a 6 nH parasitic inductance via Ansys Q3D 2025 R1 simulation, with experimental validation at 8.3 nH through double-pulse testing. Thermal evaluations up to 200 kHz indicated 109 °C peak temperature (below 175 °C datasheet limit) and low switching losses. This work provides a critical process benchmark for the micro/nano-manufacturing of high-density SiC modules. Full article

The goal of this paper is to evaluate the life of HVDC extruded cables subjected to the extension of qualification test (EQT) load cycles, introduced by Cigrè Technical Brochure 852, as well as to compare the results thus obtained with those formerly obtained by the authors in the case of the prequalification test (PQT) load cycles. This goal has been achieved in the present investigation by properly modifying a previously developed procedure for the life and reliability estimation of HVDC cables—implemented in Matlab^TM environment—to make it applicable to EQT load cycles in addition to PQT and type test load cycles, which are already considered in the former version of the procedure. Considering a 500 kV DC-XLPE cable as the case study, the time-varying temperature profile and electric field profile within the cable insulation are calculated. Then, the fractions of life lost and the life of the cable at five locations within the insulation thickness are evaluated by means of a proper electrothermal life model. A comparison between the electric field distributions, fractions of life lost, and cable life under EQT and PQT is carried out. In this way, important features of the EQT compared to the PQT load cycles are singled out, and eventually, a new modified extension of qualification test (MEQT) is proposed as a feasible and meaningful compromise between the pros and cons of the EQT and PQT. Full article

This paper analyzes the possibility of using averaged models to analyze the distribution of power losses in the components of a DC-DC converter including a power module. An electrothermal averaged model of a buck converter including the IGBT module was formulated. This model takes into consideration conduction and switching losses in the mentioned components, the self-heating phenomenon in each component, and mutual thermal coupling between their sub-components. It is designed for SPICE software (version PSPICE A/D 17.4). Its correctness was verified experimentally, and the results obtained were compared with the results of analyses performed with the use of PLECS software and the IGBT module model proposed by the manufacturer. The proposed model’s results show very good accuracy. Through the use of the proposed model, the dependences of the components of power losses and the case temperature of the IGBT module and the inductor on parameters describing the control signal and load of this converter were determined. The distribution of power losses in the converter components was analyzed for selected operating conditions of the buck converter. On the basis of the results obtained, some recommendations were formulated for designers of such DC-DC converters. Full article

Lithium-polymer (LiPo) batteries are valued for their high energy density, stable voltage output, low self-discharge, and strong reliability, making them a popular choice for high-performance and portable applications. Despite these advantages, the charging behavior of LiPo batteries—especially during rapid charging—remains an area with limited understanding. This research examines the electro-thermal characteristics of VARTA LiPo batteries when subjected to high charging currents (2C, 3C, and 4C rates). A temperature-sensitive charging model is developed to address safety and efficiency concerns during fast charging. Experimental data indicate that charging at 45 °C yields the best performance, achieving 80% state of charge (SoC) within 25 min. However, charging at temperatures above or below this level (such as 25 °C) reduces efficiency due to increased internal resistance and accelerated battery aging. The model, validated across a range of temperatures (25 °C, 35 °C, 45 °C, and 60 °C), shows that longer constant-current (CC) charging phases at higher temperatures are associated with lower internal resistance. These results highlight the importance of effective thermal management for optimizing both safety and performance in LiPo battery applications. Full article

Sintered silver, widely used in WBG electronic device packaging for its excellent electrothermal properties and high-temperature stability, faces challenges in macroscopic mechanical behavior and reliability due to porosity, especially for pressureless sintered silver. However, the intrinsic pores inside sintered material introduce uncertainties during nanoindentation tests for mechanical characterization. This study investigated the impact of pore distribution on the dislocation behavior of pressureless sintered silver during nanoindentation. Firstly, pressureless sintered silver models with 8–33% porosity were prepared and characterized through scanning electron microscope (SEM) for porosity, electron backscatter diffraction (EBSD) for the geometrically necessary dislocation (GND) density distribution, and transmission electron microscopy (TEM) for the crystal structure and microscopic strain. The EBSD results indicated that nanoindentation caused localized plastic deformation in sintered silver, closely related to its porous structure. The TEM results revealed that sintered silver undergoes dislocation slip during nanoindentation, leading to complex dislocation network formation, while the strain decreased with distance from the indentation. To further investigate the relationship of pore distribution and dislocation behavior during nanoindentation, molecular dynamics (MD) simulations were carried out. The MD results revealed that the dislocation distribution was consistent with the EBSD and TEM results. During loading, with the increased porosity from 10% to 23.7%, the total dislocation length was reduced by 63%, while it led to a 38% increase in total dislocation length with the average pore size decreased from 3.84 nm to 2.88 nm under similar porosity conditions. This study improves the understanding of the deformation mechanisms of porous sintered silver under nanoindentation and provides insight into the mechanical characterization of porous materials. Full article

To promote low-carbon transformation and achieve carbon peak and neutrality in the energy field, this study proposes an operational optimization model considering the energy- and load-side dual response (ELDR) mechanism for electrothermal coupled virtual power plants (VPPs) containing a carbon capture device. The organic Rankine cycle (ORC) waste heat boiler (WHB) is introduced on the energy side. The integrated demand response (IDR) of electricity and heat is performed on the load side based on comprehensive user satisfaction (CUS), and the carbon capture system (CCS) is used as a flexible resource. Additionally, a carbon capture device operation mode that makes full use of new energy and the valley power of the power grid is proposed. To minimize the total cost, an optimal scheduling model of virtual power plants under ladder-type carbon trading is constructed, and opportunity-constrained planning based on sequence operation is used to address the uncertainty problems of new energy output and load demand. The results show that the application of the ELDR mechanism can save 27.46% of the total operating cost and reduce CO₂ emissions by 45.28%, which effectively improves the economy and low carbon of VPPs. In particular, the application of a CCS in VPPs contributes to reducing the carbon footprint of the system. Full article

In the rapidly advancing digital era, the demand for miniaturized and high-performance electronic devices is increasing, particularly in applications such as wireless communication, unmanned aerial vehicles, and healthcare devices. Radio-frequency microelectromechanical systems (RF MEMS), particularly RF MEMS switches, play a crucial role in enhancing RF performance by providing low-loss, high-isolation switching and precise signal path control in reconfigurable RF front-end systems. Among different configurations, electrothermally actuated bistable lateral RF MEMS switches are preferred for their energy efficiency, requiring power only during transitions. This paper presents a novel approach to improve the RF performance of such a switch through structural modifications and machine learning (ML)-driven optimization. To enable efficient high-frequency operation, the H-clamp structure was re-engineered into various lateral configurations, among which the I-clamp exhibited superior RF characteristics. The proposed I-clamp switch was optimized using an eXtreme Gradient Boost (XGBoost) ML model to predict optimal design parameters while significantly reducing the computational overhead of conventional EM simulations. Activation functions were employed within the ML model to improve the accuracy of predicting optimal design parameters by capturing complex nonlinear relationships. The proposed methodology reduced design time by 87.7%, with the optimized I-clamp switch achieving −0.8 dB insertion loss and −70 dB isolation at 10 GHz. Full article

AC power cables play an important role in power systems, in the transmission and distribution of electrical energy. For this reason, to ensure high operational reliability, voltage withstand tests and diagnostic tests are performed at every stage of their technical life to determine the condition of cable insulation. Due to the large electrical capacitances of cable systems, modern testing methods use very low frequency (VLF) and damped oscillating (DAC) voltages. The research presented in the article analyzed the effect of the test voltage waveform parameters on the partial discharge (PD) inception conditions in spherical gaseous voids present in the XLPE insulation of AC cable model. Using COMSOL 6.1 and MATLAB R2021b, a coupled electro-thermal model of a 110 kV AC cable was implemented, for which the critical gaseous void dimensions were estimated and phase-resolved PD patterns were generated for the rated voltage and the VLF and DAC test voltages specified in the relevant standards. In the analyses for the rated voltage, the influence of internal temperature distribution, which causes modification of XLPE permittivity, was taken into account in the numerical cable model. Full article

We present a reduced-order battery management system (BMS) for lithium-ion cells in electric and hybrid vehicles that couples a physics-based single-particle model (SPM) derived from the Cahn–Hilliard phase-field formulation with a lumped heat-transfer model. A three-dimensional COMSOL^® 5.0 simulation of a LiFePO₄ particle produced voltage and temperature data across ambient temperatures (253–298 K) and discharge rates (1 C–20.5 C). Principal component analysis (PCA) reduced this dataset to five latent variables, which we then mapped to experimental voltage–temperature profiles of an A123 Systems 26650 2.3 Ah cell using a self-normalizing neural network (SNN). The resulting ROM achieves real-time prediction accuracy comparable to detailed models while retaining essential electrothermal dynamics. Full article

Lightning-induced ablation can severely compromise the structural integrity of composite materials. While metallic coatings have been widely studied for lightning protection, this study focuses on a different application—applying aluminum coatings to repaired composite materials. The goal is to address the challenge of ensuring that composite structures can withstand subsequent lightning strikes after repair. This study utilized an electro-thermal coupling finite element analysis model to assess the damage to laminates and the effectiveness of identical material patches for repairs. It is found that although patched laminates may experience more severe ablation damage when subjected to the same lightning strike, the application of an aluminum coating can significantly mitigate damage. Furthermore, this study improved the aluminum coating scheme, investigating the impact of coating width and shape on its lightning protection efficacy. The results indicate that a cross-shaped aluminum coating provides significant advantages in protecting repaired laminates against lightning strike, with a significant reduction compared to the uncoated controls. However, it was noted that narrowing the coating width could limit the coating’s ability to handle high current densities, potentially affecting its protective capabilities. These insights may contribute to the advancement of composite material repair strategies and the development of innovative protective structures against lightning damage. Full article

Industry 5.0 places growing emphasis on intelligent and efficient design methodologies aiming to reduce development times, accelerate the time-to-market, and enhance human–machine collaboration in creating new products. This article proposes the use of a model-based design (MBD) approach to developing a detailed electro-thermal model (ETDM) of a Smart Latch Mechanism (SLM) used in automotive door automation systems. The proposed ETDM enhances the accuracy of the design and verification processes and enables the simulation of specific scenarios, such as fault conditions, within a virtual environment. The simulation-based framework presented in this article leverages partial knowledge of the system to enable rapid estimations of the performance and functional validation. It encompasses the injection of disturbances, the analysis of failure scenarios, and the use of processor-in-the-loop (PIL) procedures for validation purposes. This work aims to employ detailed modeling and simulation techniques and use publicly available technical data and work from the literature to eliminate the need for physical testing and instrumentation, enabling the development of models that accurately reflect the real-world behavior under defined operating conditions. The proposed framework has the potential to facilitate rapid prototyping and system reconfiguration, contributing to shorter development cycles and improved industrial efficiency by reducing both production times and the associated costs for established automotive subsystems where high precision is nonessential. Full article