Search Results (253)

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

In response to the growing demand for lightweight and high-efficiency industrial equipment, this study addresses the critical issue of lubrication failure in high-speed, heavy-duty gear reducers, which often leads to reduced transmission efficiency and premature mechanical damage. A three-dimensional transient multiphysics-coupled model of oil-jet lubrication is developed based on computational fluid dynamics (CFD). The model integrates the Volume of Fluid (VOF) multiphase flow method with the shear stress transport (SST) k−ω turbulence model. This framework enables the accurate capture of oil-jet interface fragmentation, reattachment, and turbulence-coupled behavior within the gear meshing region. A parametric study is conducted on oil injection velocities ranging from 20 to 50 m/s to elucidate the coupling mechanisms between geometric configuration and flow dynamics, as well as their impacts on oil film evolution, energy dissipation, and thermal management. The results reveal that the proposed method can reveal the dynamic evolution characteristics of the gear injection lubrication. Adopting an appropriately moderate injection velocity (30 m/s) improves oil film coverage and continuity, with the lubricant transitioning from discrete droplets to a dense wedge-shaped film within the meshing zone. Optimal lubrication performance is achieved at this velocity, where oil shear-carrying capacity and kinetic energy utilization efficiency are maximized, while excessive turbulent kinetic energy dissipation is effectively suppressed. Dynamic monitoring data at point P further corroborate that a well-tuned injection velocity stabilizes lubricant-velocity fluctuations and improves lubricant oil distribution, thereby promoting consistent oil film formation and more efficient heat transfer. The proposed closed-loop collaborative framework—comprising model initialization, numerical solution, and post-processing—together with the introduced quantitative evaluation metrics, provides a solid theoretical foundation and engineering reference for structural optimization, energy control, and thermal reliability design of gearbox lubrication systems. This work offers important insights into precision lubrication of high-speed transmissions and contributes to the sustainable, green development of industrial machinery. Full article

This study introduces a paradigm shift in permanent magnet synchronous motor (PMSM) control through the development of hybrid dual fractional-order sliding mode control (HDFOSMC) architecture integrated with evolutionary parameter learning (EPL). Conventional PMSM control frameworks face critical limitations in ultra-precision applications due to their inability to reconcile dynamic agility with steady-state precision under time-varying parameters and compound disturbances. The proposed HDFOSMC framework addresses these challenges via two synergistic innovations: (1) a dual fractional-order sliding manifold that fuses the rapid transient response of non-integer-order differentiation with the small steady-state error capability of dual-integral compensation, and (2) an EPL mechanism enabling real-time adaptation to thermal drift, load mutations, and unmodeled nonlinearities. Validation can be obtained through the comparison of the results on PMSM testbenches, which demonstrate superior performance over traditional fractional-order sliding mode control (FOSMC). By integrating fractional-order theory, sliding mode control theory, and parameter self-tuning theory, this study proposes a novel control framework for PMSM. The developed system achieves high-precision performance under extreme operational uncertainties through this innovative theoretical synthesis and comparative results. Full article

This study investigates the thermal response and surface modification of low-carbon manganese-alloyed 20GL steel during electrolytic plasma hardening. The objective was to evaluate the feasibility of surface hardening 20GL steel—traditionally considered difficult to quench—by combining high-rate surface heating with rapid cooling in an electrolyte medium. To achieve this, a transient two-dimensional heat conduction model was developed to simulate temperature evolution in the steel sample under three voltage regimes. The model accounted for dynamic thermal properties and non-linear boundary conditions, focusing on temperature gradients across the thickness. Experimental temperature measurements were obtained using a K-type thermocouple embedded at a depth of 2 mm, with corrections for sensor inertia based on exponential response behavior. A comparison between simulation and experiment was conducted, focusing on peak temperatures, heating and cooling rates, and the effective thermal penetration depth. Microhardness profiling and metallographic examination confirmed surface strengthening and structural refinement, which intensified with increasing voltage. Importantly, the study identified a critical cooling rate threshold of approximately 50 °C/s required to initiate martensitic transformation in 20GL steel. These findings provide a foundation for future optimization of quenching strategies for low-carbon steels by offering insight into the interplay between thermal fluxes, surface kinetics, and process parameters. Full article

Transient increments of X-ray radiation and extreme ultraviolet (EUV) during solar flares are strong drivers of thermospheric dynamics on Mars, yet their class-dependent impacts remain poorly measured. This work provides the first direct, side-by-side study of Martian thermospheric reactions to flares X8.2 on 10 September 2017 and M6.0 on 17 September 2017. This study shows nonlinear, class-dependent effects, compositional changes, and recovery processes not recorded in previous investigations. Species-specific responses deviated significantly from irradiance proportionality, even though the soft X-ray flux in the X8.2 flare was 13 times greater. Argon (Ar) concentrations rose 3.28× (compared to 1.13× for M6.0), and radiative cooling led CO₂ heating to approach a halt at ΔT = +40 K (X8.2) against +19 K (M6.0) at exobase altitudes (196–259 km). N₂ showed the largest class difference, where temperatures rose by +126 K (X8.2) instead of +19 K (M6.0), therefore displaying flare-magnitude dependent thermal sensitivity. The 1.95× increase in O concentrations during X8.2 and the subsequent decrease following M6.0 (−39 K cooling) illustrate the contradiction between photochemical production and radiative loss. The O/CO₂ ratio at 225 km dropped 46% during X8.2, revealing compositional gradients boosted by flares. Recovery timeframes varied by class; CO₂ quickly re-equilibrated because of effective cooling, whereas inert species (Ar, N₂) stabilized within 1–2 orbits after M6.0 but needed >10 orbits of the MAVEN satellite after the X8.2 flare. The observations of the X8.2 flare came from the western limb of the Sun, but the M6.0 flare happened on the far side. The CME shock was the primary driver of Mars’ EUV reaction. These findings provide additional information on atmospheric loss and planetary habitability by indicating that Mars’ thermosphere has a saturation threshold where strong flares induce nonlinear energy partitioning that encourages the departure of lighter species. Full article

In this paper, we develop a peridynamic computational framework to analyze thermomechanical interactions in fractured thin films subjected to ultrashort-pulsed laser excitation, employing nonlocal discrete material point discretization to eliminate mesh dependency artifacts. The generalized Cattaneo–Fourier thermal flux formulation uncovers contrasting dynamic responses: hyperbolic heat propagation ($F_T=0$) generates intensified temperature localization and elevates transient crack-tip stress concentrations relative to classical Fourier diffusion ($F_T=1$). A GSSSS (Generalized Single Step Single Solve) i-Integration temporal scheme achieves oscillation-free numerical solutions across picosecond-level laser–matter interactions, effectively resolving steep thermal fronts through adaptive stabilization. These findings underscore hyperbolic conduction’s essential influence on stress-mediated fracture evolution during ultrafast laser processing, providing critical guidelines for thermal management in micro-/nano-electromechanical systems. Full article

This study presents a comprehensive finite element investigation into the design optimization of an ultra-high temperature ceramic matrix composite thruster for green bipropellant systems. Focusing on ZrB₂–SiC–Cfiber composites, it explores their thermal and mechanical response under realistic transient combustion conditions. Two geometries, a simplified and a complex full-featured model, were evaluated to assess the impact of geometric fidelity on stress prediction. The complex thruster model (CTM) offered improved resolution of temperature gradients and stress concentrations, especially near flange and convergent regions, and was adopted for optimization. A parametric study with nine wall thickness profiles identified a 2 mm tapered configuration in both convergent and divergent sections that minimized mass while maintaining structural integrity. This optimized profile reduced peak thermal stress and overall mass without compromising safety margins. Transient thermal and strain analyses showed that thermal stress dominates initially (≤3 s), while thermal strain becomes critical later due to stiffness degradation. Damage risk was evaluated using temperature-dependent stress margins at four critical locations. Time-dependent failure maps revealed throat degradation for short burns and flange cracking for longer durations. All analyses were conducted under hot-fire conditions without cooling. The validated methodology supports durable, lightweight nozzle designs for future green propulsion missions. Full article

The structural fire of post-tensioned concrete flat slabs with unbonded tendons has not been well investigated so far. An investigation based on experimental results was conducted in this study using a numerical model. Three-dimensional nonlinear finite element models of the flat slabs were established by employing the software ABAQUS, where nonlinear material models of concrete and prestressing steel tendons at elevated temperatures were incorporated. Meanwhile, both the transient creep strain of concrete and thermal creep strain of prestressing steel were explicitly considered, based on which the numerical results obtained agreed well with those of the tests for vertical displacements and crack patterns of slabs. The variations in the tendon stresses were examined as well. The effects of tendon distribution, level of prestressing, and slab soffit area exposed to fire were investigated in relation to the structural responses of the slabs. Tendon distribution had a minor effect, while the level of prestressing and area exposed to fire had significant effects. Full article

This study addresses the issue of frequency instability caused by an imbalance between load power and generation power in a power system. A state-space model of a two-area power system including a thermal power plant is first established, incorporating the output power limitations of the energy storage system, which is the actuator for frequency control. Under input saturation constraints, a frequency control strategy based on a prescribed performance control technique is proposed. This strategy not only ensures frequency stability but also achieves an optimal transient response curve. The proposed control strategy is theoretically validated and numerically simulated, demonstrating its effectiveness in suppressing frequency variations in power systems under constraints regarding the output power of the energy storage system. Full article

When a semiconducting sample is illuminated by an intensity-modulated monochromatic light beam with photon energy exceeding the band gap, part of the absorbed energy is directly converted into heat through photon–lattice interactions. This gives rise to a heat source that closely follows the temporal profile of the optical excitation, known as the fast heat source. Simultaneously, another portion of the absorbed energy is used to generate electron-hole pairs. These charge carriers diffuse together and recombine via electron–electron and electron–hole interactions, transferring their kinetic energy to the lattice and producing additional heating of the sample. This indirect heating mechanism, associated with carrier recombination, is referred to as the slow heat source. In this study, we develop a model describing surface temperature variations on the non-illuminated side of a thermally thin semiconductor exposed to a rectangular optical pulse, explicitly accounting for the contribution of surface charge carrier recombinations. Using this model, we investigate the influence of surface recombination velocity and the material’s plasma properties on the time-domain temperature response for both plasma-opaque and plasma-transparent samples. Our results demonstrate that charge carrier recombinations can significantly affect the transient photoacoustic signal recorded using a minimum volume cell, highlighting the potential of time-resolved photoacoustic techniques for probing the electronic properties of semiconductors. Full article

This study improved the thermal damping of concrete with rice husk ash (RHA)–fly ash (FA) matrix and three phase-change material (PCM) aggregates with phase change temperatures between −15 and 5 °C, which are expected to reduce winter energy consumption in cold regions when used as building envelope structures. Firstly, the strength of concrete was studied. Secondly, the dynamic and transient thermal response of concrete was evaluated through thermal conductivity and thermal diffusivity. Based on nuclear magnetic resonance experiments, the changes in the pore volume and fractal dimension of RHA–FA matrix and PCM aggregate added to concrete were studied. Through correlation analysis, a macroscopic performance prediction model based on pore characteristics was obtained. The results indicated that the incorporation of PCM aggregate reduced concrete strength, while an appropriate RHA–FA matrix contributed to enhancing concrete strength. Both the PCM aggregate and RHA–FA matrix were beneficial for improving the thermal damping properties of concrete. For 15% RHA–30% FA 100% PCM concrete, the thermal conductivity can be reduced by 53%, the thermal diffusivity can be reduced by 64%, the limiting temperature decreased by 5.5 °C, and the thermal damping coefficient increased by 48%. The nuclear magnetic resonance test results showed that PCM aggregate increased the pore volume and decreased the fractal dimension, while an appropriate RHA–FA matrix helped to reduce the pore volume. The macroscopic properties of RHA–FA–PCM aggregate concrete were highly correlated with the capillary pore volume and fractal dimension. A two-parameter prediction model based on pore characteristics can effectively predict the macroscopic properties of concrete. Full article

Precise temperature control in high-temperature furnaces is challenged by nonlinearities, parameter drift, and high thermal inertia. This study proposes an adaptive control strategy combining a classical PID loop with real-time gain updates from a feed-forward artificial neural network (ANN). Implemented on an 18 kW retrofitted Blue-M furnace, the system was characterized by second-order transfer functions for heating and forced convection cooling. A dataset of 9702 samples was built from eight fixed PID configurations tested under a multi-ramp thermal profile. The selected 3-64-64-32-2 ANN, executed in Python and interfaced with LabVIEW, computes optimal gains in 0.054 ms while preserving real-time monitoring capabilities. Experimental results show that the ANN-assisted PID reduces the mean absolute error to 5.08 °C, limits overshoot to 41% (from 53%), and shortens settling time by 20% compared to the best fixed-gain loop. It also outperforms a fuzzy controller and remains stable under ±5% signal noise. Notably, gain reversals during cooling prevent temperature spikes, improving transient response. Relying on commodity hardware and open-source tools, this approach offers a cost-effective solution for legacy furnace upgrades and provides a replicable model for adaptive control in high-temperature, safety-critical environments like metal processing, battery cycling, and nuclear systems. Full article

Efficient thermal management is critical for the performance, safety, and longevity of lithium-ion batteries, particularly in new energy vehicles. This paper presents the development and application of a NiCr/NiSi thin-film thermocouple fabricated via magnetron sputtering on a polyimide substrate, aiming to provide high-precision, fast-response internal temperature measurements for lithium-ion battery systems. The thermocouple demonstrates a Seebeck coefficient of approximately 40.95 μV/°C and a repeatability error of only 0.45%, making it highly suitable for capturing transient thermal events. The main innovation of this work lies in the comprehensive integration of simulation and experimental validation to optimize the thermocouple’s performance for lithium-ion battery applications. This includes static calibration, external short-circuit, and puncture tests, which collectively confirm the thermocouple’s reliability and accuracy. Additionally, the study explores the impact of ambient temperature variations on internal battery temperatures, revealing a nearly linear increase in internal temperature with rising ambient conditions. The findings offer valuable insights for improving battery thermal management systems, establishing early warning thresholds for thermal runaway, and enhancing the overall safety of lithium-ion battery applications. Full article

This study presents the calibration methodology of NiCr-NiSi thin-film thermocouples and evaluates their application in real-time temperature monitoring and characterization of fuel cell thermal behavior. Experimental results reveal that the Seebeck coefficients of the NiCr-NiSi thin films remain stable after multiple calibration cycles, indicating good reliability and repeatability. Furthermore, the thermocouples demonstrate an ultrafast response time of less than 15 microseconds and reach thermal equilibrium within 200 microseconds under transient thermal inputs. These characteristics enable accurate and rapid temperature measurement of fuel cell plates up to 100 °C, which is critical for maintaining the safe and efficient operation of fuel cells. Full article

This paper presents a comprehensive analytical framework for investigating loss mechanisms and thermal behavior in high-speed magnetic field-modulated motors for flywheel energy storage systems. Through systematic classification of electromagnetic, mechanical, and additional losses, we reveal that modulator components constitute approximately 45% of total system losses at rated speed. Finite element analysis demonstrates significant spatial non-uniformity in loss distribution, with peak loss densities of 5.5 × 10⁵ W/m³ occurring in the modulator region, while end-region losses exceed central-region values by 42% due to three-dimensional field effects. Our optimized design, implementing composite rotor structures, dual-material permanent magnets, and integrated thermal management solutions, achieves a 43.2% reduction in total electromagnetic losses, with permanent magnet eddy current losses decreasing by 68.7%. The maximum temperature hotspots decrease from 143 °C to 98 °C under identical operating conditions, with temperature gradients reduced by 58%. Peak efficiency increases from 92.3% to 95.8%, with the η > 90% region expanding by 42% in the speed–torque plane. Experimental validation confirms model accuracy with mean absolute percentage errors below 4.2%. The optimized design demonstrates 24.8% faster response times during charging transients while maintaining 41.7% smaller speed oscillations during sudden load changes. These quantitative improvements address critical limitations in existing systems, providing a viable pathway toward high-reliability, grid-scale energy storage solutions with extended operational lifetimes and improved round-trip efficiency. Full article