Search Results (747)

The efficiency of electric motors is highly dependent on their operating temperature, with lower temperatures contributing to enhanced performance, reliability, and extended service life. This study presents a comprehensive review of state-of-the-art cooling technologies and evaluates their impact on the thermal behavior of a commercial motor–generator system in high-demand applications. A baseline model of a permanent magnet synchronous motor (PMSM) was developed using MotorCAD 2023^® software, which was supported by reverse engineering techniques to accurately replicate the motor’s physical and thermal characteristics. Subsequently, multiple cooling strategies were simulated under consistent operating conditions to assess their effectiveness. These strategies include conventional axial water jackets as well as advanced oil-based methods such as shaft cooling and direct oil spray to the windings. The integration of these systems in hybrid configurations was also explored to maximize thermal efficiency. Simulation results reveal that hybrid cooling significantly reduces the temperature of critical components such as stator windings and permanent magnets. This reduction in thermal stress improves current efficiency, power output, and torque capacity, enabling reliable motor operation across a broader range of speeds and under sustained high-load conditions. The findings highlight the effectiveness of hybrid cooling systems in optimizing both thermal management and operational performance of electric machines. 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 a new air treatment system that integrates dehumidification, cooling, and water recovery using a Horizontal Air–Ground Heat Exchanger (HAGHE) combined with Peltier cells. The airflow generated by a fan flows through an HAGHE until it meets a septum on which Peltier cells are placed, and then separates into two distinct streams that lap the two surfaces of the Peltier cells: one stream passes through the cold surfaces, undergoing both sensible and latent cooling with dehumidification; the other stream passes through the hot surfaces, increasing its temperature. The two treated air streams may then pass through a mixing chamber, where they are combined in the appropriate proportions to achieve the desired air supply conditions and ensure thermal comfort in the indoor environment. A Computational Fluid Dynamics (CFD) analysis was carried out to simulate the thermal interaction between the HAGHE and the surrounding soil. The simulation focused on a system installed under the subtropical climate conditions of Nairobi, Africa. The simulation results demonstrate that the HAGHE system is capable of reducing the air temperature by several degrees under typical summer conditions, with enhanced performance observed when the soil is moist. Condensation phenomena were triggered when the relative humidity of the inlet air exceeded 60%, contributing additional cooling through latent heat extraction. The proposed HAGHE–Peltier system can be easily powered by renewable energy sources and configured for stand-alone operation, making it particularly suitable for off-grid applications. Full article

The growing global demand for electricity, driven by the development of electromobility, data centers, and smart technologies, necessitates innovative approaches to energy generation. Wind power, as a clean and renewable energy source, plays a pivotal role in the global transition towards low-carbon power systems. This paper presents a comprehensive review of generator technologies used in wind turbine applications, ranging from conventional synchronous and asynchronous machines to advanced concepts such as low-speed direct-drive (DD) generators, axial-flux topologies, and superconducting generators utilizing low-temperature superconductors (LTS) and high-temperature superconductors (HTS). The advantages and limitations of each design are discussed in the context of efficiency, weight, reliability, scalability, and suitability for offshore deployment. Special attention is given to HTS-based generator systems, which offer superior power density and reduced losses, along with challenges related to cryogenic cooling and materials engineering. Furthermore, the paper analyzes selected modern generator designs to provide references for enhancing the performance of grid-synchronized hybrid microgrids integrating solar PV, wind, battery energy storage, and HTS-enhanced generators. This review serves as a valuable resource for researchers and engineers developing next-generation wind energy technologies with improved efficiency and integration potential. 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

This study investigates the application of the Analytic Hierarchy Process (AHP) as a decision-support mechanism for managing complex sustainability issues in industrial settings, specifically within the framework of circular economy principles. Focusing on a case from the brewery sector, developed under the EU ECOFACT initiative, this research evaluates ten distinct configurations for the must cooling process. These alternatives are assessed using environmental, economic, and technical criteria, drawing on data from life cycle assessment (LCA) and life cycle costing (LCC) methodologies. The findings indicate that selecting an optimal scenario involves balancing trade-offs among electricity and water consumption, operational efficiency, and overall environmental impacts. Notably, Scenario 3 emerges as the most balanced option, consistently demonstrating superior performance across the primary evaluation criteria. The use of AHP in this context proves valuable by introducing structure and transparency to a multifaceted decision-making process where quantitative metrics and sustainability objectives intersect. By integrating empirical industrial data with an established multi-criteria decision approach, this study highlights both the practical utility and existing limitations of conventional AHP, particularly its diminished ability to discriminate between alternatives when their scores are closely aligned. These insights suggest that hybrid or advanced AHP methodologies may be necessary to facilitate more nuanced decision-making for circular economy transitions in industrial environments. Full article

The current research trends of production engineering are based on optimizing the machining process concerning human and environmental factors. High-performance materials, such as hardened steels, nickel-based alloys, fiber-reinforced polymer (FRP) composites, and titanium alloys, are classified as hard-to-cut due to their ability to maintain strength at high operating temperatures. Due to these characteristics, such materials are employed in applications such as aerospace, marine, energy generation, and structural. The purpose of this article is to investigate the machinability of these alloys under various cutting conditions. The purpose of this article is to compare cryogenic cooling and cryogenic processing from the perspective of machinability and sustainability in the manufacturing process. Compared to conventional machining, hybrid techniques, which mix cryogenic and minimal quantity lubricant, led to significantly reduced cutting forces of 40–50%, cutting temperatures and surface finishes by approximately 20–30% and more than 40%, respectively. A carbon footprint is determined by several factors including power consumption, energy requirements, and carbon dioxide emissions. As a result of the cryogenic technology, the energy consumption, power consumption, and CO₂ emissions were reduced by 40%, 28%, and 35%. Full article

The transition to electric vehicles (EVs) is accelerating due to global efforts to reduce greenhouse gas emissions and reliance on fossil fuels. Lithium-ion batteries (LIBs) are the predominant energy storage solution in EVs, offering high energy density, efficiency, and long lifespan. However, their adoption is overly involved with critical safety concerns, including thermal runaway and overheating. This review systematically focuses on the critical role of battery thermal management systems (BTMSs), such as active, passive, and hybrid cooling systems, in maintaining LIBs within their optimal operating temperature range, ensuring temperature homogeneity, safety, and efficiency. Additionally, the study explores the impact of integrating artificial intelligence (AI) and machine learning (ML) into BTMS on thermal performance prediction and energy-efficient cooling, focusing on optimizing the operating parameters of cooling systems. This review provides insights into enhancing LIB safety and performance for widespread EV adoption by addressing these challenges. Full article

Nickel-based superalloy Hastelloy C276 is widely used in high-performance industries due to its strength, corrosion resistance, and thermal stability. However, these same properties pose substantial challenges in machining, resulting in high tool wear, surface defects, and dimensional inaccuracies. This study investigates methods to enhance machining performance and surface quality by evaluating the tribological behavior of TiSiN/TiAlN-coated carbide inserts under six cooling and lubrication conditions: dry, MQL with coconut oil, Cryo-LN₂, Cryo-LCO₂, MQL–Cryo-LN₂, and MQL–Cryo-LCO₂. Open-slot finishing was performed at constant cutting parameters, and key indicators such as cutting zone temperature, tool wear, surface roughness, chip morphology, and microhardness were analyzed. The hybrid MQL–Cryo-LN₂ approach significantly outperformed other methods, reducing cutting zone temperature, tool wear, and surface roughness by 116.4%, 94.34%, and 76.11%, respectively, compared to dry machining. SEM and EDS analyses confirmed abrasive, oxidative, and adhesive wear as the dominant mechanisms. The MQL–Cryo-LN₂ strategy also lowered microhardness, in contrast to a 39.7% increase observed under dry conditions. These findings highlight the superior performance of hybrid MQL–Cryo-LN₂ in improving machinability, offering a promising solution for precision-driven applications. Full article

The construction sector presently consumes about 40% of global energy and generates 36% of CO₂ emissions, making facade retrofits a priority for decarbonising buildings. This review clarifies how ventilated facades (VFs), wall assemblies that interpose a ventilated air cavity between outer cladding and the insulated structure, address that challenge. First, the paper categorises VFs by structural configuration, ventilation strategy and functional control into four principal families: double-skin, rainscreen, hybrid/adaptive and active–passive systems, with further extensions such as BIPV, PCM and green-wall integrations that couple energy generation or storage with envelope performance. Heat-transfer analysis shows that the cavity interrupts conductive paths, promotes buoyancy- or wind-driven convection, and curtails radiative exchange. Key design parameters, including cavity depth, vent-area ratio, airflow velocity and surface emissivity, govern this balance, while hybrid ventilation offers the most excellent peak-load mitigation with modest energy input. A synthesis of simulation and field studies indicates that properly detailed VFs reduce envelope cooling loads by 20–55% across diverse climates and cut winter heating demand by 10–20% when vents are seasonally managed or coupled with heat-recovery devices. These thermal benefits translate into steadier interior surface temperatures, lower radiant asymmetry and fewer drafts, thereby expanding the hours occupants remain within comfort bands without mechanical conditioning. Climate-responsive guidance emerges in tropical and arid regions, favouring highly ventilated, low-absorptance cladding; temperate and continental zones gain from adaptive vents, movable insulation or PCM layers; multi-skin adaptive facades promise balanced year-round savings by re-configuring in real time. Overall, the review demonstrates that VFs constitute a versatile, passive-plus platform for low-carbon buildings, simultaneously enhancing energy efficiency, durability and indoor comfort. Future advances in smart controls, bio-based materials and integrated energy-recovery systems are poised to unlock further performance gains and accelerate the sector’s transition to net-zero. Emerging multifunctional materials such as phase-change composites, nanostructured coatings, and perovskite-integrated systems also show promise in enhancing facade adaptability and energy responsiveness. Full article

This study investigates a hybrid manufacturing approach that combines 3D printing and injection molding to extend the limitations of each individual technique. Injection molding is often limited by high initial tooling costs, long lead times, and restricted geometric flexibility, whereas 3D-printed molds tend to suffer from material degradation, extended cooling times, and lower surface quality. By integrating 3D-printed molds into the injection-molding process, this hybrid method enables the production of complex geometries with improved cost-efficiency. The approach is demonstrated using a range of polymeric materials, including ABS, nylon, and polyurethane foam—each selected to enhance the mechanical and thermal performance of the final products. Finite element method (FEM) analysis was conducted to assess thermal distribution, deformation, and stress during manufacturing. Results indicated that both temperature and stress remained within safe operational limits for 3D-printed materials. An economic analysis revealed substantial cost savings compared to fully 3D-printed components, establishing hybrid manufacturing as a viable and scalable alternative. This method offers broad industrial applicability, delivering enhanced mechanical properties, design flexibility, and reduced production costs. Full article

Cryosurgery employs extremely low temperatures to destroy abnormal or cancerous tissue. Conventional systems use cryogenic fluids like liquid nitrogen or argon, which pose challenges in handling, cost, and precise temperature control. This study explores thermoelectric (TE) cooling using the Peltier effect as an efficient alternative. A numerical optimization of multi-stage TE coolers using bismuth telluride (Bi₂Te₃) is performed through finite element analysis in COMSOL Multiphysics. Results show that the optimized multi-stage TE system achieves a minimum temperature of −70 °C, a 90 K temperature difference, and 4.0 W cooling power—outperforming single-stage (SS) systems with a maximum ΔT of 73.27 K. The study also investigates the effects of material properties, current density, and geometry on performance. An optimized multi-stage (MS) configuration improves cooling efficiency by 22.8%, demonstrating the potential of TE devices as compact, energy-efficient, and precise solutions for cryosurgical applications. Future work will explore advanced nanomaterials and hybrid systems to further improve performance in biomedical cooling. Full article

Permeate Gap Membrane Distillation (PGMD) is an emerging desalination technology that offers a promising alternative for freshwater production, particularly in energy-efficient and sustainable applications. This review provides a comprehensive analysis of PGMD, covering its fundamental principles, heat and mass transfer mechanisms, and key challenges such as temperature and concentration polarization. Various optimisation strategies, including Response Surface Morphology (RSM), Differential Evolution techniques, and Computational Fluid Dynamics (CFD) modelling, are explored to enhance PGMD performance. The study further discusses the latest advancements in system design, highlighting optimal configurations and the integration of PGMD with renewable energy sources. Factors influencing PGMD performance, such as operational parameters (flow rates, temperature, and feed concentration) and physical parameters (gap width, membrane properties, and cooling plate conductivity), are systematically analysed. Additionally, the techno-economic feasibility of PGMD for large-scale freshwater production is evaluated, with a focus on cost reduction strategies, energy efficiency, and hybrid system innovations. Finally, this review outlines the current limitations and future research directions for PGMD, emphasising novel system modifications, improved heat recovery techniques, and potential industrial applications. By consolidating recent advancements and identifying key challenges, this paper aims to guide future research and facilitate the broader adoption of PGMD in sustainable desalination and water purification processes. Full article

Energy demand in the building sector has drastically increased due to rising occupant comfort requirements, accounting for 30% of the world’s final energy consumption and 26% of global carbon emissions. Thus, to improve building efficiency in heating and cooling applications, phase change material (PCM)-based passive thermal management techniques have been considered due to their energy storage capabilities. This study provides a comprehensive review of the research on PCM applications, types, and encapsulation forms. Various solutions have been proposed to enhance PCM performance. In this review, the authors suggest new methods to improve PCM efficiency by using the multilayered wall technique, which involves employing two layers of a hybrid bio-composite—specifically, the hybrid hemp/wood fiber-reinforced composite with a polypropylene (PP) matrix—along with a layer of PCM made from spent coffee grounds (SCGs). Previous studies have shown that oil extracted from SCGs demonstrates good thermal and chemical stability, as it contains approximately 60–80% fatty acids, with a phase transition temperature of approximately 4.5 ± 0.72 °C and latent heat values of 51.15 ± 1.46 kJ/kg. Full article