Search Results (53)

The energy-intensive nature of primary aluminum production necessitates advanced computational tools for process optimization. This study presents a coupled electro-thermal model of an aluminum reduction cell, developed within the framework of smart manufacturing. Using the finite difference method (FDM) implemented in MATLAB R2025b, the model resolves the three-dimensional configuration of a cell with eight prebaked anodes across four distinct physical domains (electrolyte, anodes, cathode, and gas phase). The computational grid comprises approximately 45,000 nodes with refined vertical resolution (Δz = 0.025 m) in the interelectrode gap. The electrostatic solution converges within 150–200 iterations using successive over-relaxation (SOR, ω = 1.5), with a total runtime under 15 min for 30,000 s of simulated physical time on a standard desktop workstation. Simulation results reveal characteristic temperature profiles with maxima reaching 1150 °C and a thermal uniformity index of approximately 130 °C across the central cross-section. The predicted specific energy consumption of 14.0 MWh/t Al aligns with industrial benchmarks. This computationally accessible virtual testbed enables rapid assessment of design modifications and process parameters, supporting the goals of energy efficiency and enhanced operational stability in primary aluminum production. Full article

Cellulose paper, a natural polymeric dielectric, determines the lifetime of oil–paper insulation systems in transformers, yet its molecular degradation behavior in ester-based insulating media remains insufficiently clarified. This study investigates the electro–thermal aging of cellulose polymer immersed in soybean-based natural ester (SBNE) and palm fatty acid ester (PFAE), with emphasis on depolymerization and its relationship with partial discharge (PD) activity. Accelerated aging experiments were conducted under combined electrical and thermal stress, and the evolution of the degree of polymerization (DP) was measured to quantify polymer chain scission. Phase-resolved PD (PRPD) patterns were recorded during aging, and multi-dimensional statistical features were extracted and reduced using principal component analysis to characterize degradation-sensitive electrical responses. The results show a progressive decrease in DP with aging time in both ester media, accompanied by distinct PD evolution characteristics, indicating different influences of the two esters on cellulose polymer stability. An ensemble learning model integrating multiple classifiers was further employed to identify aging stages based on PD features, achieving reliable discrimination performance. These findings establish a correlation between cellulose depolymerization and dielectric discharge behavior, providing a polymer-centered interpretation of aging mechanisms in ester-based oil–paper insulation systems. Full article

Transparent heaters intended for skin-contacting applications must simultaneously satisfy optical transparency, mechanical compliance, thermal uniformity, and operational safety under biologically relevant temperature ranges. Here, we evaluate the applicability of a TiO₂/Ag/SiO₂ (TAS) dielectric–metal–dielectric transparent heater as a functional biomaterial platform for wearable and skin-integrated thermal systems. By systematically optimizing each layer thickness of the TAS structure, the heater achieves high visible-light transmittance (average of 86.6%) together with low sheet resistance on the order of 7.7 Ω/sq for low-voltage operation. The TAS heater demonstrates rapid and reproducible Joule-heating behavior, showing fast thermal response with short thermal time constants and spatially homogeneous temperature distributions without localized hot spots. Stable electrothermal performance is maintained under repeated on/off cycling and during cyclic mechanical bending down to small radii, confirming excellent mechanical stability under repeated bending relevant to wearable applications. Importantly, direct on-skin evaluations conducted by attaching the device to a human elbow reveal conformal contact, uniform heating at therapeutically relevant temperatures (50–70 °C), and stable operation under dynamic bending and extension. The absence of thermal inhomogeneity during motion highlights the intrinsic stability of the TAS architecture for skin-interfaced use. Given the high optical visibility, mechanical compliance, thermal uniformity, and electrothermal stability, the proposed TAS architecture represents a promising functional biomaterial platform for wearable thermotherapy, skin-mounted healthcare devices, and human-interactive thermal systems operating under continuous mechanical deformation and direct skin contact. Full article

The global population explosion and accelerated industrialization have led to an increasing shortage of fossil fuels and environmental contamination, underscoring the urgent need to develop innovative energy storage technologies to improve energy utilization efficiency. As pivotal components in thermal energy storage (TES) systems, phase change materials (PCMs) enable spatiotemporal matching between thermal energy supply and demand through latent heat absorption and release during phase transitions. Organic PCMs are considered ideal candidates for thermal energy storage due to their high energy storage density, stable phase transition temperature, low supercooling, and negligible phase separation. However, inherent drawbacks such as low thermal conductivity, liquid leakage, limited light absorption, and lack of functionality have hindered their widespread application in advanced thermal management systems. Herein, we systematically summarize cutting-edge functionalization strategies for PCMs, progressing from conventional methods like thermal conductive particle blending and microencapsulation to the emerging design of 3D porous thermally conductive skeletons, including metal foams, boron nitride aerogels, carbon-based aerogels, and MXene aerogels. These frameworks not only enhance thermal transport via continuous conductive pathways and impart shape stability through capillary encapsulation but also, when integrated with photo-thermal, electro-thermal, and magneto-thermal conversion properties, enable broad applications in solar photo-thermal/photo-thermo-electric conversion, thermal management of electronics and batteries, building efficiency, and wearable thermal regulation. The review further addresses current challenges and future directions, highlighting scalable 3D framework fabrication, the shift to active thermal management, and innovative applications beyond conventional domains. By establishing a microstructure–property–application correlation, this work provides valuable insights for developing next-generation high-performance multifunctional phase change composites. Full article

Standalone photovoltaic systems play an important role in providing reliable renewable energy in remote areas. These systems depend heavily on battery energy storage, especially lithium iron phosphate batteries, which are known for their safety and long cycle life. However, battery degradation remains a major challenge, as high charging currents, temperature variations, and wide state-of-charge fluctuations introduce electro-thermal stress that reduces the useful lifetime of the storage system. To address this issue, this paper presents a Flexible Power Point Tracking (FPPT) strategy supported by a fuzzy-logic-based controller. In this context, battery stress refers to the combined electrochemical and thermal stress induced by high charging currents, elevated operating temperatures, and large state-of-charge (SOC) excursions, which are known to accelerate ageing mechanisms and capacity fade. Based on a review of the existing literature, most FPPT and lifetime-oriented control studies have focused on lithium-ion batteries such as NMC or LCO chemistries, while limited attention has been given to lithium iron phosphate (LiFePO₄) batteries. The goal is to limit battery stress by reducing current peaks, mitigating temperature rise, and smoothing state-of-charge variations, thereby improving battery lifetime without compromising the stability of the standalone PV system. A complete PV–battery model is developed in PLECS and tested using one-year irradiance, temperature, and load data from Perth, Australia. The results show that the FPPT–Fuzzy controller reduces current peaks, stabilises the state of charge, and lowers the thermal impact on the battery when compared with traditional MPPT. As a result, overall degradation decreases and the battery lifetime is extended by approximately 7%. These findings demonstrate that FPPT is a promising method for improving the long-term performance of renewable energy systems based on lithium iron phosphate battery storage. Full article

To combat the critical hurdles of thermal buildup and low-temperature shutdown events in 5G-enabled smart wearables, a high-performance flexible composite film based on ellagic acid-modified single-walled carbon nanotubes (EA-SWCNTs) and aramid nanofibers (ANF) was designed and developed. The influence mechanism of the loading amount of the conductive network on the electrothermal properties of the composite material was focused on. The results show that through the π-π stacking non-covalent modification strategy, the uniform dispersion of EA-SWCNTs on the layer of ANF substrate and the construction of an ordered layered structure were successfully achieved. The prepared composite film could reach a steady-state temperature of 171 °C under a driving voltage of 3.5 V. In addition, it exhibits excellent electrothermal response characteristics and cyclic stability. It could reach the steady-state voltage within 10 s and shows no obvious performance degradation after multiple cycles. This composite film shows broad application prospects in fields such as intelligent wearable devices and flexible electronic protection. Full article

To address the limitation of the IEC 60287 standard in accurately representing the electrothermal characteristics of cables under different grounding conditions, this study proposes a modified equivalent thermal resistance method, using a YJLW03-Z 64/110 1 × 1200 mm² high-voltage single-core cable as a case study to analyze three typical grounding modes, namely two-end solid bonding, segmented solid bonding, and semiconductive outer sheath. Equivalent circuit models are established to calculate the induced current, voltage, and losses of the metallic sheath and armor. Based on these results, the equivalent thermal resistance model is modified, and correction formulas for cable ampacity considering grounding effects are derived. The proposed model is validated through numerical simulations under typical laying conditions and field tests conducted in Zhoushan, Zhejiang Province. Results show that grounding modes significantly influence the electromagnetic losses and temperature distribution of cables. Segmented solid bonding effectively reduces sheath losses and increases ampacity, while its enhancement tends to stabilize beyond two bonding sections. The semiconductive outer sheath improves electric field distribution and thermal stability with limited ampacity gain. This study provides theoretical guidance and engineering reference for optimizing grounding designs, ampacity evaluation, and digital operation of high-voltage cable systems. Full article

The development of electro-thermal textiles has attracted growing interest as a promising approach for active thermal management in wearable systems. Metallic-coated fabrics can efficiently generate heat through the Joule effect; however, their long-term performance and safety are severely limited under perspiration due to metal ion release and corrosion. To overcome these challenges, this study introduces a Parylene-C encapsulation strategy for copper-coated polyethylene terephthalate nonwovens (CuPET) using a chemical vapor deposition (CVD) process. The conformal, biocompatible Parylene-C films (thickness 4–16 μm) act as effective protective barriers while preserving the porous textile structure. Morphological and comfort analyses demonstrate a controlled reduction in air permeability from 3100 to 1100 L·m⁻²·s⁻¹, maintaining acceptable breathability. Electro-thermal measurements reveal rapid and uniform heating, reaching 40–45 °C within 2 min at 2 V, and the addition of a thermal insulation layer further enhances the Joule heating efficiency, increasing the steady-state temperature by approximately 6 °C. ICP–OES results show an ≈80% reduction in copper ion release (from 28.34 mg·L⁻¹ to 5.80 mg·L⁻¹) after artificial sweat exposure. This work demonstrates a scalable encapsulation route that effectively balances sweat protection, electrical stability, and thermal performance, paving the way for safe, durable, and actively heated smart textiles for advanced thermal insulation applications. Full article

Reliable multilevel inverter IGBT modules require precise loss and heat management, particularly in severe traction applications. This paper presents a comprehensive modeling framework for three-level T-type neutral-point clamped (TNPC) inverters using a high-power Insulated Gate Bipolar Transistor (IGBT) module that combines model predictive control (MPC) with space vector pulse width modulation (SVPWM). The particle swarm optimization (PSO) algorithm is used to methodically tune the MPC cost function weights for minimization, while achieving a balance between output current tracking, stabilization of the neutral-point voltage, and, consequently, a uniform distribution of thermal stress. The proposed SVPWM-MPC algorithm selects optimal switching states, which are then utilized in a chip-level loss model coupled with a Cauer RC thermal network to predict transient chip-level junction temperatures dynamically. The proposed framework is executed in MATLAB R2024b and validated with experiments, and the SemiSel industrial thermal simulation tool, demonstrating both control effectiveness and accuracy of the electro-thermal model. The results demonstrate that the proposed control method can sustain neutral-point voltage imbalance of less than 0.45% when operating at 25% load and approximately 1% under full load working conditions, while accomplishing a uniform junction temperature profile in all inverter legs across different working conditions. Moreover, the results indicate that the proposed control and modeling structure is an effective and common-sense way to perform coordinated electrical and thermal management, effectively allowing for predesign and reliability testing of high-power TNPC inverters. Full article

The reliability and lifetime of insulated gate bipolar transistors (IGBTs) are critical to ensuring the stability and safety of power electronic systems. IGBTs are widely used in electric vehicles, renewable energy systems, and industrial automation. However, their degradation over time poses a significant risk to system performance. Therefore, this paper proposes a data-driven approach based on a Long Short-Term Memory (LSTM) network optimized by a Genetic Algorithm (GA) to predict IGBT degradation. The study examines the health monitoring of insulated gate bipolar transistors from a device physics perspective. Degradation mechanisms that alter parasitics and electro-thermal stress produce characteristic changes in the turn-off overvoltage and the on-state voltage. Using power-cycling data from packaged half-bridge modules, an LSTM-based sequence model configured by a genetic algorithm search reduces error against an identically trained baseline (RMSE = 0.0073, MAE = 0.057, MAPE = 0.726%) under the shared protocol, with the clearest advantages in the early stage of degradation. These results support predictive maintenance and health management in power-electronic systems. Full article

The operational stability and performance of dual active bridge (DAB) converters are dictated by an intricate coupling of electrical, magnetic, and thermal dynamics. Conventional modeling paradigms fail to capture these interactions, creating a critical gap between design predictions and real performance. A unified Port-Hamiltonian model (PHM) is developed, embedding nonlinear, temperature-dependent material physics within a single, energy-conserving structure. Derived from first principles and experimentally validated, the model reproduces high-frequency dynamics, including saturation-driven current spikes, with superior fidelity. The energy-based structure systematically exposes the converter’s stability boundaries, revealing not only thermal runaway limits but also previously obscured electro-thermal oscillatory modes. The resulting framework provides a rigorous foundation for the predictive co-design of magnetics, thermal management, and control, enabling guaranteed stability and optimized performance across the full operational envelope. Full article

This work presents a novel Gallium Nitride (GaN) high-electron-mobility transistor (HEMT)-based ultraviolet (UV) photodetector architecture that integrates advanced material and structural design strategies to enhance detection performance and stability under room-temperature operation. This study is conducted as a fully numerical simulation using the Silvaco Atlas platform, providing detailed electrothermal and optoelectronic analysis of the proposed device. The device is constructed on a high-thermal-conductivity silicon carbide (SiC) substrate and incorporates an n-GaN buffer, an indium nitride (InN) channel layer for improved electron mobility and two-dimensional electron gas (2DEG) confinement, and a dual-passivation scheme combining silicon nitride (SiN) and hexagonal boron nitride (h-BN). A p-GaN layer is embedded between the passivation interfaces to deplete the 2DEG in dark conditions. In the device architecture, the metal contacts consist of a 2 nm Nickel (Ni) adhesion layer followed by Gold (Au), employed as source and drain electrodes, while a recessed gate embedded within the substrate ensures improved electric field control and effective noise suppression. Numerical simulations demonstrate that the integration of a hexagonal boron nitride (h-BN) interlayer within the dual passivation stack effectively suppresses the gate leakage current from the typical literature values of the order of ${10}^{-8}$ A to approximately ${10}^{-10}$ A, highlighting its critical role in enhancing interfacial insulation. In addition, consistent with previous reports, the use of a SiC substrate offers significantly improved thermal management over sapphire, enabling more stable operation under UV illumination. The device demonstrates strong photoresponse under 360 nm ultraviolet (UV) illumination, a high photo-to-dark current ratio (PDCR) found at approximately ${10}^6$, and tunable performance via structural optimization of p-GaN width between 0.40 μm and 1.60 μm, doping concentration from $5\times {10}^{16}$ ${\mathrm{cm}}^{-3}$ to $5\times {10}^{18}$ ${\mathrm{cm}}^{-3}$, and embedding depth between 0.060 μm and 0.068 μm. The results underscore the proposed structure’s notable effectiveness in passivation quality, suppression of gate leakage, and thermal management, collectively establishing it as a robust and reliable platform for next-generation UV photodetectors operating under harsh environmental conditions. Full article

This study investigates the electro-thermal transient response of a photovoltaic–thermal (PV/T)–heat pump system under dynamic disturbances to optimize operational stability. A dynamic model integrating a PV/T collector and a heat pump was developed by the transient heat current method, enabling high-fidelity simulations of step perturbations: solar irradiance reduction, compressor operation, condenser water flow rate variations, and thermal storage tank volume changes. This study highlights the thermal storage tank’s critical role. For V_tank = 2 m³, water tank volume significantly suppresses the water tank and PV/T collector temperature fluctuations caused by solar irradiance reduction. PV/T collector temperature fluctuation suppression improved by 46.7%. For the PV/T heat pump system in this study, the water tank volume was selected between 1 and 1.5 m³ to optimize the balance of thermal inertia and cost. Despite PV cell electrical efficiency gains from PV cell temperature reductions caused by solar irradiance reduction, power recovery remains limited. Compressor dynamic performance exhibits asymmetry: the hot water temperature drop caused by speed reduction exceeds the rise from speed increase. Load fluctuations reveal heightened risk: load reduction triggers a hot water 7.6 °C decline versus a 2.2 °C gain under equivalent load increases. Meanwhile, water flow rate variation in condenser identifies electro-thermal time lags (100 s thermal and 50 s electrical stabilization), necessitating predictive compressor control to prevent temperature and compressor operation oscillations caused by system condition changes. These findings advance hybrid renewable systems by resolving transient coupling mechanisms and enhancing operational resilience, offering actionable strategies for PV/T–heat pump deployment in building energy applications. Full article

Soft electrothermal actuators have attracted increasing attention in soft robotics and wearable systems due to their simple structure, low driving voltage, and ease of integration. However, traditional designs based on homogeneous or layered composites often suffer from interfacial failure and limited deformation modes, restricting their long-term stability and actuation versatility. In this study, we present a programmable soft electrothermal actuator based on a functionally graded structure composed of polydimethylsiloxane (PDMS)/multiwalled carbon nanotube (MWCNTs) composite material and an embedded EGaIn conductive circuit. Rheological and mechanical characterization confirms the enhancement of viscosity, modulus, and tensile strength with increasing MWCNTs content, confirming that the gradient structure improves mechanical performance. The device shows excellent actuation performance (bending angle up to 117°), fast response (8 s), and durability (100 cycles). The actuator achieves L-shaped, U-shaped, and V-shaped bending deformations through circuit pattern design, demonstrating precise programmability and reconfigurability. This work provides a new strategy for realizing programmable, multimodal deformation in soft systems and offers promising applications in adaptive robotics, smart devices, and human–machine interfaces. 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