Search Results (16)

In this study, prevention of fracture in vibration fatigue testing of automotive alternator heatsink blocks was investigated using an artificial neural network. Automotive components such as alternator heatsink blocks are subjected to high cyclic vibration fatigue loads throughout their lifespan, which can lead to the formation and propagation of fatigue cracks and ultimately component failure. The basic parameters affecting the resonant frequency of the heatsink blocks, including geometry and loading conditions, are determined. Data-driven decision making provides advanced predictive insights to analyze data for prediction and decisions using artificial intelligence approaches. An efficient artificial neural network model was defined to predict the resonance frequency in the vibration fatigue test. While the artificial neural network was trained to establish a functional relationship between the parameters and the resonance frequency, regression analysis was used to develop a predictive model to detect the resonance frequency of the heatsinks. The proposed approach aims to provide a comprehensive framework for preventing fracture problems in vibration fatigue tests of automotive alternator heatsinks and ultimately contribute to the reliable design and performance of these critical components. While the artificial neural network approach achieved high classification accuracy in predicting the new natural frequency, the regression model was also able to make accurate predictions. The results of this study showed that the time spent on design and simulation can be significantly reduced in preventing breakage problems that may occur before dynamic tests such as vibration tests of alternator components. Full article

Flexible thermoelectric generators (FTEGs) have garnered significant attention for their potential in harnessing waste heat energy from various sources. To optimize their efficiency, FTEGs require efficient and adaptable heatsinks. In this study, we propose a cost-effective solution by integrating phase-change materials into FTEG heatsinks. We developed and tested three flexible phase-change material thicknesses (4 mm, 7 mm, and 10 mm), focusing on preventing leaks during operation. Additionally, we investigated the impact of wind speed on the output performance of FTEGs with a flexible phase-change material heatsink. The results indicate that the appropriate flexible phase-change material thickness, when integrated with considerations for wind speed, demonstrates remarkable heat-absorbing capabilities at phase-change temperatures. This integration enables substantial temperature differentials across the FTEG modules. Specifically, the FTEG equipped with a 10 mm thick flexible phase-change material heatsink achieved a power density more than four times higher when the wind speed was at 1 m/s compared to no wind speed. This outcome suggests that integrating phase-change material heatsinks with relatively low wind speeds can significantly enhance flexible thermoelectric generator efficiency. Finally, we present a practical application wherein the FTEG, integrated with the flexible phase-change material heatsink, efficiently converts waste heat from a circular hot pipe into electricity, serving as a viable power source for smartphone devices. This work opens exciting possibilities for the future integration of flexible thermoelectric modules with flexible phase-change material heatsinks, offering a promising avenue for converting thermal waste heat into usable electricity. Full article

The increased adoption of photovoltaic (PV) systems for global decarbonisation necessitates addressing the gap in reduced panel efficiency due to overheating. This issue is especially prominent in countries with extremely hot and humid climates where PV utilisation is hindered by declining panel output. A systematic review of PV cooling techniques suggests passive systems are more economical, sustainable, and easier to implement than active systems, despite possessing a lower cooling potential. Air-based systems were deemed the most viable for the UAE’s climate, considering both performance and cost. Based on these findings, two individual improvements for air-based cooling systems were combined in an attempt to achieve greater cooling: a segmented multiangular aluminium fin heatsink developed from previous works. Various perforation patterns were simulated on the chosen heatsink using CFD software to determine the most optimal arrangement. The original and optimised models were both tested under real-life conditions in Dubai, United Arab Emirates, revealing similar cooling potential between the two. The results of this study indicate that the PV cell temperature can be decreased by up to 10 °C with the placement of an aluminium fin heatsink, which corresponds to an approximate efficiency increase of 5%. Full article

This work investigated the potential for waste heat recovery from a cement factory using thermoelectric generation (TEG) technology. Several TEGs were placed on a secondary coaxial shell separated from the kiln shell by an air gap. The performance of the system was tested and evaluated experimentally. Two cooling methods, active water and forced air, were considered. A forced closed-loop water cooling system with a heat exchanger was considered for the active-water cooling method. A heat exchanger was inserted before the water tank to improve cooling efficiency by reducing the inlet temperature of the cooling water tank, in contrast to forced-air cooling, in which a heatsink was used. The obtained results indicated that the closed-loop water-cooled system equipped with a radiator, i.e., active water, has the highest conversion efficiency. The maximum absorbed heat for the forced-air and active-water cooling systems were 265.03 and 262.95 W, respectively. The active-water cooling method improves the power of TEG by 4.4% in comparison with forced-air cooling, while the payback periods for the proposed active-water and forced-air cooling systems are approximately 16 and 9 months, respectively. Full article

Bond wire lift-off is one of the major failure mechanisms in the insulated gate bipolar transistor (IGBT) modules. Detecting the fault of bond wires is important to avoid the open-circuit fault of IGBT to ensure the reliable operation of power converters. In this paper, we propose a novel bond wire fatigue detection method for IGBT, which could be used in normal working conditions. Firstly, we investigated the dependence of bond wire fatigue on heatsink thermal resistance. An aging rate K was proposed to compare the measured thermal resistance with the initial value, which could indicate the bond wire fatigue. Then, this proposed method was verified by simulation and experimental results under different current levels. Finally, a power cycling test was used to show the aging process of the IGBT module, which shows the feasibility of proposed method. Full article

In the case of light-emitting diode (LED) seaport luminaires, they should be designed in consideration of glare, average illuminance, and overall uniformity. Although it is possible to implement light distribution through auxiliary devices such as reflectors, it means increasing the weight and size of the luminaire, which reduces the feasibility. Considering the special environment of seaport luminaires, which are installed at a height of 30 m or more, it is necessary to reduce the weight of the device, facilitate replacement, and secure a light source with a long life. In this paper, an optimized lens design was investigated to provide uniform light distribution to meet the requirement in the seaport lighting application. Four types of lens were designed and fabricated to verify the uniform light distribution requirement for the seaport lighting application. Using numerical analysis, we optimized the lens that provides the required minimum overall uniformity for the seaport lighting application. A theoretical analysis for the heatsink structure and shape were conducted to reduce the heat from the high-power LED light sources up to 250 W. As a result of these analyses on the heat dissipation characteristics of the high-power LED light source used in the LED seaport luminaire, the heatsink with hexagonal-shape fins shows the best heat dissipation effect. Finally, a prototype LED seaport luminaire with an optimized lens and heat sink was fabricated and tested in a real seaport environment. The light distribution characteristics of this prototype LED seaport luminaire were compared with a commercial high-pressure sodium luminaire and metal halide luminaire. Full article

This paper addresses the concept of load balancing in the operation of parallel insulated-gate bipolar transistors (IGBTs), in which the temperature is used as the main control parameter. In parallel IGBT operation, it is essential to ensure an equal load distribution across all IGBTs. Two basic algorithm concepts for temperature control were developed for the purpose of balancing. A test model based on the parallel IGBTs operation was assembled in a laboratory and the developed algorithms were tested for the chosen parameters. MATLAB was used for final data processing. The comparison between the two implemented basic algorithms provides insights into the temperature behavior of parallel IGBTs in terms of individual IGBT’s heating and cooling trajectories and time constants. All tests were conducted without the heatsinks to obtain the worst-case scenario in terms of thermal conditions. The test results show that temperature control in the operation of parallel IGBTs is possible but limited. Full article

In this paper, the marine predator algorithm (MPA) is proposed for solving transcendental nonlinear equations in a selective harmonic elimination technique using a multilevel inverter (MLI). It proved its suitability and supremacy over the other selective harmonic (SHE) techniques used in recent research as it has good precision, high probability of convergence, and improving quality of output voltage. The optimum values of switching angles from MPA are applied to control a three-phase 11-level MLI using cascaded H-bridge (CHB) topology to control the fundamental component and cancel the low order harmonics for all values of modulation index from 0 to 1. Analytical and simulation results demonstrate the robustness and consistency of the technique through the MATLAB simulation platform. The results obtained from simulation show that the MPA algorithm is more efficient and accurate than other algorithms such as teaching-learning-based optimization (TLBO), flower pollination algorithm (FPA), and hybrid particle swarm optimization with gray wolf optimization (PSOGWO). A prototype for a three-phase seven-level cascaded H-bridge inverter (7L-MLI-CHB) experimental setup is carried out. The output of this experimental test validated and supported the results obtained from the simulation analysis. The model of power loss of three-phase 7L-MLI-CHB using the silicon metal-oxide-semiconductor field-effect transistor (MOSFET) is obtained according to the modulation technique. Conduction and switching losses are calculated based on the experimental manufacturer data from the Si-MOSFET using the thermal model of Piecewise Linear Electrical Circuit Simulation (PLECS). Losses and output power are measured at different modulation index values based on the MPA algorithm. Finally, a design of heatsink volume is presented for this design at different temperatures. Full article

Thermally conductive films play a crucial role in expanding the lifetime of electronics by dissipating concentrated heat to heatsinks. In this work, a thermally conductive film (g-TC film) was manufactured using a perforated graphite sheet (p-GS) and a UV-curable pressure-sensitive adhesive (PSA) by lamination. A novel UV-curable PSA was prepared by incorporating a UV-curable abietic acid ester into a PSA composition. The UV-curable PSA became a tack-free film upon UV irradiation; thus, a flexible g-TC film with a 52-μm thickness was obtained. The defects in the g-TC film caused by air bubbles were removed by treating the p-GS with oxygen plasma. As the UV-cured PSA made a joint through the holes in the p-GS, cleavage of the graphite was not observed after 10,000 U-folding test cycles with a folding radius of 1 mm. The calculated in-plane thermal conductivity of the fabricated g-TC film was 179 W∙m⁻¹K⁻¹, which was stable after the U-folding tests. Full article

In this paper, an analysis of the geometry, numerical modeling, and experimental verification of thermofoil heaters for low-temperature applications is presented. The research suggests a calculation procedure of the thermofoil traces’ geometry, comprising the necessary electrical and thermal parameters in order for the characteristics of the heater to be fully defined according to the stipulated conditions required. The derived heaters’ geometry analysis procedure is depicted with two case studies, giving the sequence of the necessary calculations and their applications as part of a design task. Its continuation, the design approach, is developed with numerical modeling, based on Finite Element Methods (FEM) used for multiphysics simulations, including the thermal and electrical heaters parameters. The realized 3D models are used to depict the uniformity of the thermal field in the system heatsink-thermofoil heater. The results from analysis, modeling, and simulations are tested experimentally. The suggested geometry analysis and modeling approach are experimentally verified. The final results demonstrate satisfactory precision with a simulation–experiment mismatch in a range of 5–7%. As a vital product of experimental research, the maximum power density for the studied thermofoil heaters is derived for a range of temperatures and material characteristics. Full article

Power electronics technology is widely used in several areas, such as in the railways, automotive, electric vehicles, and renewable energy sectors. Some of these applications are safety critical, e.g., in the automotive domain. The heat produced by power devices must be efficiently dissipated to allow them to work within their operational thermal limits. Moreover, numerous ageing effects are due to thermal stress, which causes mechanical issues. Therefore, the reliability of a circuit depends on its dissipation system, even if it consists of a simple passive heatsink mounted on the power device. During the Printed Circuit Board (PCB) production, an incorrect assembly of the heatsink can cause a worse heat dissipation with a significant increase of the junction temperatures (T_j). In this paper, three possible test strategies are compared for testing the correct assembling of heatsinks. The considered strategies are used at the PCB end-manufacturing. The effectiveness of the different test methods considered is assessed on a case study corresponding to a Power Supply Unit (PSU). Full article

An InAs/InGaAs quantum dot laser with a heterostructure epitaxially grown on a silicon substrate was used to fabricate injection microdisk lasers of different diameters (15–31 µm). A post-growth process includes photolithography and deep dry etching. No surface protection/passivation is applied. The microlasers are capable of operating heatsink-free in a continuous-wave regime at room and elevated temperatures. A record-low threshold current density of 0.36 kA/cm² was achieved in 31 µm diameter microdisks operating uncooled. In microlasers with a diameter of 15 µm, the minimum threshold current density was found to be 0.68 kA/cm². Thermal resistance of microdisk lasers monolithically grown on silicon agrees well with that of microdisks on GaAs substrates. The ageing test performed for microdisk lasers on silicon during 1000 h at a constant current revealed that the output power dropped by only ~9%. A preliminary estimate of the lifetime for quantum-dot (QD) microlasers on silicon (defined by a double drop of the power) is 83,000 h. Quantum dot microdisk lasers made of a heterostructure grown on GaAs were transferred onto a silicon wafer using indium bonding. Microlasers have a joint electrical contact over a residual n+ GaAs substrate, whereas their individual addressing is achieved by placing them down on a p-contact to separate contact pads. These microdisks hybridly integrated to silicon laser at room temperature in a continuous-wave mode. No effect of non-native substrate on device characteristics was found. Full article

Much biomedical research focuses on the effects of UV light on human cells. UV light sources are a prerequisite for such research. This paper presents the design and achieved performance of a UVA (Ultraviolet A: 320–400 nm) and a UVB (Ultraviolet B: 290–320 nm) LED-based lamp suitable for use in bioassays, as well as inside an incubator. Numerical simulations were used to optimise the number, layout and output power of LEDs to achieve good irradiance homogeneity while maintaining low costs. Design was optimised for the efficient transfer of generated heat away from the irradiated samples through the heatsink at the back of the lamps. The average irradiance of the target surface by the UVA lamp was 70.1 W/m² with a maximum deviation of 4.9%, and the average irradiance by the UVB lamp was 3.1 W/m² with a maximum deviation of 4.8%. With the UVA and UVB lamps, the temperature of samples undergoing irradiation in the incubator rises from 37 to 42 °C within 40 and 67 min, respectively. This by far exceeds the required UV irradiation time in most cases. Tests on Jurkat and HEK-293 cell cultures confirmed the suitability of our lamps for biomedical research. Full article

The scope of thermoelectric generators (TEGs), in improving the electric vehicle battery performance and glass/steel manufacturing industries, could achieve wider significance by harnessing the unused radiative heat and light conversion to electrical power. This paper experimentally investigates the electrical performance correlated to concentrated quartz-halogen, with acrylic Fresnel lens and heat-light harvesting, coupled with heat sink. This study also experimentally examined the influence of extreme temperature variance on the open circuit generated voltage of the Peltier electrical failure mode, compared to the standard performance parameters of the commercial TEG module. The research results presented provide expedient perception into the testing (open circuit voltage, short circuit current, and full load power) of a commercial heat-stove TEG to understand its performance limitations. The analytical simulation and mathematical model developed in MATLAB compared the electrical performance parameters and its dependencies. The analytical simulation shows that increasing the heat-sink temperature increases the efficiency of not more than 2% at the $\Delta T$ of 360 K, due to the limitation of the $Z\overline{T}$ of 0.43 at $\Delta T$ of 390 K. The maximum $Z\overline{T}$ of 0.7 for Bi₂Te₃, with an achievable efficiency of 4.5% at the Seebeck coefficient of 250 µV/K, was predicted. The design of three experimental setups and results presented demonstrate the functioning of TEG in stable and unstable temperature conditions, confirming the theoretical study and stipulating a quantity of the electrical output power in relation to extreme temperature conditions. Full article

The performance optimization of the two-level, three-phase, grid-feeding, voltage-source inverter (VSI) is studied in this paper, which adopts an online adaptive switching frequency algorithm (OASF). A new degree of freedom has been added to the employed OASF algorithm for optimal selection of the weighting factor and overall system optimization design. Toward that end, a full mathematical formulation, including the impact of the coupling inductor and the controller response time, is presented. At first, the weighting factor is selected to favor the switching losses, and the controller gains are optimized by minimizing the integral time-weighted absolute error (ITAE) of the output active and reactive power. Different loading and ambient temperature conditions are considered to validate the optimized controller and its fast response through online field programmable gate array (FPGA)-in-the-loop. Then, the weighting factor is optimally selected to reduce the cost of the L-filter and the heat-sink. An optimization problem to minimize the cost design at the worst case of loading condition for grid-feeding VSI is formulated. The results from this optimization problem are the filter inductance, the thermal resistance of the heat-sink, and the optimal switching frequency with the optimal weighting factor. The VSI test-bed using the optimized parameters is used to verify the proposed work experimentally. Adopting the OASF algorithm that employs the optimal weighting factor for grid-feeding VSI, the percentages of the reductions in the slope of the steady state junction temperature profile compared to fixed frequencies of 10 kHz, 14.434 kHz, and 20 kHz are about 6%, 30%, and 18%, respectively. Full article