Browse Topic: Thermal management

Items (1,517)
With the increasingly prominent environmental problems and energy crisis, wind power, solar power and other new energy has been rapid development, and energy storage technology is of great significance to the development of new energy. Compared with the power batteries applied in electric vehicles, battery energy storage systems gather a larger number of batteries and a larger scale, usually up to megawatts or 100 megawatts. During the operation of the energy storage system, the lithium-ion battery continues to charge and discharge, and its internal electrochemical reaction will inevitably generate a lot of heat. If the heat is not dispersed in time, the temperature of the lithium-ion battery will continue to rise, which will seriously affect the service life and performance of the battery, and even cause thermal runaway leading to explosion. It is of great significance for promoting the development of new energy technologies to carry out research on the thermal model of lithium-ion
Chen, JianxiangLi, LipingZhou, FupengLi, ChunchengShangguan, Wen-Bin
Electric vehicles (EVs) are gaining popularity due to their zero tailpipe emissions, superior energy efficiency, and sustainable nature. EVs have various limitations, and crucial one is the occurrence of thermal runaway in the battery pack. During charging or discharging condition of battery pack may result in thermal runaway condition. This promotes the requirement of effective cooling arrangement in and around the battery pack to avoid localized peak temperature. In the present work, thermal management of a 26650 Lithium iron phosphate (LFP) cell using natural convection air cooling, composite biobased phase change material (CBPCM) and its combination with copper fins is numerically investigated using multi-scale multi dimension - Newman, Tiedenann, Gu and Kim (MSMD-NTGK) battery model in Ansys Fluent at an ambient temperature of 306 K. Natural convection air cooling was found effective at discharge rates of 1C to 3C, maintaining cell temperature below the safe limit of 318 K for 80
Srivastav, DurgeshPatil, Nagesh DevidasShukla, Pravesh Chandra
Thermal runaway in battery cells presents a critical safety concern, emphasizing the need for a thorough understanding of thermal behavior to enhance battery safety and performance. This study introduces a newly developed AutoLion 3D thermal runaway model, which builds on the earlier AutoLion 1D framework and offers significantly faster computational performance compared to traditional CFD models. The model is validated through simulations of the heat-wait-search mode of the Accelerating Rate Calorimeter (ARC), accurately predicting thermal runaway by matching experimental temperature profiles from peer-reviewed studies. Once validated, the model is employed to investigate the thermal behavior of 3D LFPO cells under controlled heating conditions, applying heat to one or more surfaces at a time while modeling heat transfer from non-heated surfaces. The primary objective is to understand how these localized heating patterns impact temperature profiles, including average core temperatures
Hariharan, DeivanayagamGundlapally, Santhosh
Thermal runaway is a critical phenomenon in lithium batteries, characterized by a self-sustaining process due to internal chemical reactions, that is triggered once a certain temperature is reached within the cell. This event is often caused by overheating due to charge and discharge cycles and can lead to fires or explosions, posing a significant safety threat. The aim of this study is to induce thermal runaway on single cells in different ways to characterize the phenomenon and validate the simulation models present in Altair SimLab®. The work was conducted in several key phases. Initially, an experimental test was performed in a calorimeter (EV ARC HWS test) to collect temperature data of the Molicel 21700 P45B cell during thermal runaway under adiabatic conditions. These data were used for a simulation on a single cell, allowing a detailed comparison with the experimental results. Subsequently, a test was conducted on a single cell under operational conditions, overheated using a
Giuliano, LucaScrimieri, LuigiReitano, SimoneBerti Polato, DavideFerraris, AlessandroComerford, AndrewBhatnagar, Saakaar
Charging a battery electric vehicle at extreme temperatures can lead to battery deterioration without proper thermal management. To avoid battery degradation, charging current is generally limited at extreme hot and cold battery temperatures. Splitting the wall power between charging and the thermal management system with the aim of minimizing charging time is a challenging problem especially with the strong thermal coupling with the charging current. Existing research focus on formulating the battery thermal management control problem as a minimum charging time optimal control problem. Such control strategy force the driver to charge with minimum time and higher charging cost irrespective of their driving schedule. This paper presents a driver-centric DCFC control framework by formulating the power split between thermal management and charging as an optimal control problem with the goal of improving the wall-to-vehicle energy efficiency. Proposed energy-efficient charging strategy
Gupta, ShobhitKang, Jun-MoZhu, YongjieLee, ChunhaoZanardelli, Wesley
A method for performance calculation and experimental method of a high voltage heater system in electric vehicles is proposed. Firstly, heater outlet temperature and pressure drop of the heater are used as metrics to compare simulation results with experimental data, thereby validating the established model. Then, simulations are performed on two heater flow channel configurations: a cavity flow channel and a cooling fin flow channel. It is observed that the latter significantly reduces the heating plate temperature. This reduction enhances the protection of heating elements and extends their operational lifespan, demonstrating the advantages of incorporating cooling fins into the flow channel structure. The optimization variables for multi-objective optimization include the fin unit length, fin height, fin thickness, fin width, and spacing between two adjacent rows of fins. The optimization objectives include pressure drop, heat transfer efficiency, and heating plate temperature
Gong, MingWang, XihuiWang, DongdongShangguan, Wen-Bin
With better performance and usage of clean and renewable energy, electric vehicles have ushered in more and more consumers’ favor nowadays. However, insufficient driving range especially in hot and cold ambient conditions still greatly restricts the extensive application of electric vehicles. This paper presents a methodology of establishing multi-discipline coupled full vehicle model in AMESim to investigate the energy consumption and driving range of an electric vehicle in normal and hot ambient conditions. Full vehicle energy consumption test was carried out in the climate chamber to check the accuracy of simulation results. Firstly, basic framework of the full vehicle model established in AMESim was introduced. Next, modeling details of sub-systems including vehicle dynamic system, electrical system, coolant circuit system, air-conditioning system and control strategy were illustrated. Then, full vehicle energy consumption tests were carried out in 23°C and 38°C ambient conditions
Zhou, ShuaiLiu, HuaijuYu, HuiliYan, XuYan, Junjie
Proton exchange membrane fuel cell (PEMFC) is widely used in transportation and high-efficiency energy systems for their high power density and rapid start-up capability. The temperature control of its thermal management system is characterized by slow response and system oscillation, and the temperature control process suffers from problems such as large temperature fluctuations and slow temperature rise during cold starts. To effectively control the fuel cell thermal management system, this paper proposes a fuzzy PID-based control strategy to optimize the temperature control of the stack by comprehensively controlling the cooling fan, thermostat, temperature control valve, and heat components. By modeling the 60kW PEMFC thermal management system on the MATLAB/Simulink platform, the flow distribution and heat exchange of each component are analyzed and the optimized fuzzy control strategy is compared with the traditional PID control strategy. The simulation results show that the
Zhang, YilongZhang, YunqingGuo, JunWu, Jinglai
Optimal control of battery electric vehicle thermal management systems is essential for maximizi ng the driving range in extreme weather conditions. Vehicles equipped with advanced heating, ventilation and air-conditioning (HVAC) systems based on heat pumps with secondary coolant loops are more challenging to control due to actuator redundancy and increased thermal inertia. This paper presents the dynamic programming (DP)-based offline control trajectory optimization of heat pump-based HVAC aimed at maximizing thermal comfort and energy efficiency. Besides deriving benchmark results, the goal of trajectory optimization is to gain insights for practical hierarchical control strategy modifications to further improve real-time controllers’ performance. DP optimizes cabin inlet air temperature and flow rate to set the trade-off between thermal comfort and energy efficiency while considering the nonlinear dynamics and operating limits of HVAC system in addition to typically considered cabin
Cvok, IvanDeur, Josko
Battery cell aging and loss of capacity are some of the many challenges facing the widespread implementation of electrification in mobility. One of the factors contributing to cell aging is the dissimilarities of individual cells connected in a module. This paper reports the results of several aging experiments using a mini-module consisting of seven 5 Ah 21700 lithium-ion battery cells connected in parallel. The aging cycle comprised a constant current-constant voltage charge cycle at a 0.7C C-rate, followed by a 0.2C constant current discharge, spanning the useful voltage range from minimum to maximum according to the cell manufacturer. Charge and discharge events were separated by one-hour rest periods and were repeated for four weeks. Weekly reference performance tests were executed to measure static capacity, pulse power capability and resistance at different states of charge. All diagnostics were normalized with respect to their starting numbers to achieve a percentage change
Swarts, AndreSalvi, Swapnil S.Juarez Robles, Daniel
In driving condition, the electric drive system of electric vehicles generates significant heat, which increases temperature of the motor, leading to reduced performance and energy loss. To manage the motor temperature and recover energy, a plate-fin heat exchanger (PFHE) is used to facilitate heat exchange between the electric drive system and the vehicle's thermal management system. In this study, Computational Fluid Dynamics (CFD) method was used to investigate the fin structure on thermal flow performance within the PFHE. The mathematical models of pressure drop and heat transfer of plate-fin heat exchanger are established in this paper, and an empirical formula for the friction factor was derived by using test data. The NTU method was applied to fit the formula of convective heat transfer coefficient, enabling the derivation of an empirical formula for the Colburn factor. A CFD simulation model was developed for a local heat exchange unit, considering the generic boundary
Yin, JintaiYin, ZhihongLu, XuanWang, MengmengLiu, Qian
This study investigates the impact of various notch geometries on the outer surface of the rotor of an interior permanent magnet synchronous motor intended for traction applications, focusing on improving both its thermal and electromagnetic performances. Traditional motor cooling methods, such as water jackets or oil spray/impingement, typically target the stator and/or end windings, neglecting rotor cooling. As a result, the dissipation of the heat from the rotor is dependent on the heat transfer across the air gap surrounding the rotor, despite air’s poor thermal conductivity, which causes it to act as an insulator. Rotor notches are used to limit the higher order harmonics from air gap flux density which results in decreased torque ripple, cogging torque, noise, and vibration of the machine. While the effect of rotor notches on electromagnetic performance is analyzed, their impact on the thermal management of the motor, particularly the heat transfer coefficient in the air gap
Zajac, ArthurDe Silva, BuddhikaLee, SunMistry, JigarNasirizarandi, RezaJianu, OfeliaKar, Narayan
The electric vehicle thermal management system is a critical sub-systems of electric vehicles, and has a substantial impact on the driving range. The objective of this paper is to optimize the performance of the heat pump air conditioning system, battery, and motor thermal management system by adopting an integrated design. This approach is expected to effectively improve the COP (Coefficient of Performance) of cabin heating. An integrated thermal management system model of the heat pump air conditioning system, battery, and motor thermal management system is established using AMEsim. Key parameters, such as refrigerant temperature, pressure, and flow rate at the outlet of each component of the system are compared with the measured data to verify the correctness of the model established in this paper. Using the established model, the impact of compressor speed on the heating comfort of the cabin under high-temperature conditions in summer was studied, and a control strategy for rapid
Zhang, MinLi, LipingZhou, JianhuaHuang, YuZhen, RanShangguan, Wen-Bin
The use of lithium-ion batteries in electric vehicles marks a major progression in the automotive sector. Energy storage systems extensively make use of these batteries. The extended life cycle, low self-discharge rates, high energy density, and eco-friendliness of lithium-ion batteries are well-known. However, Temperature sensitivity has an adverse effect on lithium-ion battery safety, durability, and performance. Thus, maintaining ideal operating conditions and reducing the chance of thermal runaway depend heavily on efficient thermal management. To address this, experimental study was conducted on various battery thermal management techniques, including active, passive, and hybrid approaches. These techniques were investigated for their cooling efficiencies under different operating conditions. The electro-thermal behavior of cylindrical lithium-ion battery cells, battery packs, and supervisory control techniques were simulated in the study using MATLAB Simulink, Simscape, and
Thangaraju, ShanmuganathanN, MeenakshiGanesan, Maragatham
The U.S. DRIVE Electrical and Electronics Technical Team has set a goal for 2025 to achieve a power density of 33 kW/L for electric vehicle (EV) motors [1]. The increase in motor power density is highly dependent on effective thermal management within the system, making active cooling techniques like oil-jet impingement essential for continued advancements. Due to the time and expense of physical experimentation, numerical simulations have become a preferred method for design testing and optimization. These simulations often simplify the motor-winding surface into a smooth cylinder, overlooking the actual corrugated surface due to windings, thus reducing computational resources and mesh complexity. However, the coil's corrugated surface affects flow turbulence and heat transfer rates. This study utilizes three-dimensional Computational Fluid Dynamics (CFD) simulations to investigate the impingement-cooling of an Automatic Transmission Fluid (ATF) jet on a corrugated surface that
Mutyal, Jayesh RameshHaghnegahdar, AhmadGurunadhan, MohanaKonangi, SantoshChamphekar, Omkar
On electric vehicle the low voltage (nominal 12 volt) battery serves mostly as an energy storage buffer for supporting features and actuators on the 12 volt power supply network. Within an EV, unlike an internal combustion engine car, as there is no cranking requirement needed to be supported by this battery, it presents a significant opportunity for downsizing. In a premium car there are a significant number of features which inhibits the car to go into “deep sleep” and hence remains on a “stand-by” mode of operation. During this period of stand-by the low voltage energy storage system needs to cater for up to 0.4 W when in sleep/standby mode of operation. To sustain longer periods of stand-by mode the low voltage battery needs to have enough stored energy to maintain the appropriate level of state of charge (SOC) so that enough critical threshold of SOC is maintained for 12 volts essential system startup at vehicle restart. This can potentially inhibit downsizing of the low voltage
Dutta, NilabzaOvers, Sheldon
The rapid expansion of the global electric vehicle (EV) market has significantly increased the demand for advanced thermal management solutions. Among these, the battery cold plate is a critical component, essential for maintaining optimal battery temperatures and ensuring efficient operation. As EV batteries increase in size, the thermal management requirements become more complex, necessitating the development of new alloys with enhanced strength and thermal conductivity. These advancements are crucial for the effective dissipation of heat and the ability to withstand the mechanical stresses associated with larger and more powerful batteries. The evolving performance demands of EVs are driving material innovation within the thermal management sector. This study aims to explore the global heat exchanger market trends from a material perspective, focusing on the evolution of the mechanical and thermal properties. Specifically, we investigated the transition from the traditional AA3003
Jalili, MehdiWang, XuRazm-poosh, Hadi
In modern vehicles, effective thermal management is crucial for regulating temperatures across various components and sub-systems, ensuring optimal performance, efficiency, safety, and passenger comfort. As the industry shifts towards reducing carbon emissions, powertrain electrification - encompassing electric and hybrid vehicles - has emerged as a prominent trend. This transition introduces greater complexities, as the powertrain system must now precisely control the temperatures of not only traditional components but also batteries, power electronics, and motors. Typically, the performance of vehicle-level thermal management systems is fully evaluated only after physical prototypes are developed and tested, particularly during summer and winter road trials. Conducting development and validation at such a late stage in the development process significantly increases both development risks and costs. To address these challenges, a comprehensive vehicle-level thermal management
Xu, ZhengQiu, JieLu, YuanWang, Yingzhen
The shift towards hybrid and electric powertrains in off-road vehicles aims to enhance mobility, extend range, and improve energy efficiency. However, heat pump-based battery thermal management systems in these vehicles continue to consume significant energy, impacting overall range and efficiency. Effective thermal management is essential for maintaining battery performance and safety, particularly in extreme conditions. Although high-fidelity models can capture the complex dynamics of heat pumps, real-time control within model-based optimization frameworks often depends on simplified models, which can degrade system performance. To address this, we propose a novel data-driven grey box control-oriented model (COM) that accurately represents the thermal dynamics of a vapor-compression refrigeration-based heat pump system. This COM is integrated into a model-predictive control (MPC) framework, optimizing thermal management during transient and burst-power operations of the battery pack
Sundar, AnirudhGhate, AtharvaZhu, QilunPrucka, RobertRuan, YeefengFigueroa-Santos, MiriamBarron, Morgan
Efficient thermal management is essential for maintaining the performance and safety of large-capacity battery packs. To overcome the limitations of traditional standalone air or liquid cooling methods, which often result in inadequate cooling and uneven temperature distribution, a hybrid air-liquid cooling structure was designed. A three-dimensional model was developed, and heat transfer and fluid flow characteristics were analyzed using computational fluid dynamics (CFD) simulations. Experimental validation was carried out through discharge temperature rise tests on individual battery cells and flow resistance tests on the liquid cooling plate. The thermal performance of the hybrid system was compared to that of standalone cooling methods under various discharge rates. The results indicated that the hybrid system significantly enhanced cooling performance, reducing the maximum temperature difference by 5.54°C and 3.37°C, and the peak temperature by 11.66°C and 4.5°C, compared to air
Li, HaoGuo, YimingZhou, FupengLi, KunyuanShangguan, Wen-Bin
Phase change energy storage devices are extensively utilized in latent heat thermal energy storage and hold significant potential for application in the thermal management of automotive batteries. By harnessing the high-density energy storage capabilities of phase change materials to absorb heat released by the batteries, followed by timely release and utilization, there is a substantial improvement in energy efficiency. However, the thermal conductivity of medium and low temperature phase change materials is poor, leading to its inefficient utilization. This paper focuses on optimizing the structure of a phase change heat exchanger in a phase change energy storage device to improve its performance. A basic design of the phase change heat exchanger is used as an example, and fin structure is added to enhance its heat exchange capabilities. A predictive surrogate model is built using numerical simulation, with the dimension and number of fins as design variables, and heat flow density
Zhang, HaonanSun, MingzheZheng, HaoyunZhang, Tianming
The maximum temperature and the maximum temperature difference of lithium battery energy storage systems are of great importance to their lifespan and safety. The energy storage module targeted in this research utilizes a forced air-cooling thermal management system. In this article, the maximum battery temperature, temperature difference, and cooling fan power are used as evaluation indicators. The thermal–fluid coupling simulation technology is utilized to restore the real structure of the module, ensuring the reliability of the simulation results. The P-Q curve is introduced for the boundary conditions of the heat dissipation fan to investigate the influence of the flow channel structure on the airflow volume and distribution. First, the thermal–fluid coupling simulation results of the original structure were compared with the measured parameters. Subsequently, the study on the airflow and temperature distribution of the original flow channel structure reveals that a significant
Guo, YuChengBao, YiDongJiang, BingYunLu, FeiFei
In this article, a finite element analysis for the passenger car tire size 235/55R19 is performed to investigate the effect of temperature-dependent properties of the tire tread compound on the tire–road interaction characteristics for four seasons (all-season, winter, summer, and fall). The rubber-like parts of the tire were modeled using the hyperelastic Mooney–Rivlin material model and were meshed with the three-dimensional hybrid solid elements. The road is modeled using the rigid body dry hard surface and the contact between the tire and road is modeled using the non-symmetric node-to-segment contact with edge treatment. At first, the tire was verified based on the tire manufacturer’s data using numerical finite element analysis based on the static and dynamic domains. Then, the finite element analysis for the rolling resistance analysis was performed at three different longitudinal velocities (10 km/h, 40 km/h, and 80 km/h) under nominal loading conditions. Second, the steady
Fathi, HaniyehEl-Sayegh, ZeinabRen, Jing
The Object of research in the article is the ventilation and cooling system of bulb hydrogenerators. The Subject of study in the article is the design and efficiency of using the cooling system of various structural types for bulb hydro units. The Purpose of the work is to carry out a three-dimensional study of two cooling systems (axial and radial) of the bulb hydro unit of the Kanivskaya HPP with a rated 22 MW. Research Tasks include analysis of the main design solutions for effective cooling of bulb-type hydrogenerators, in particular, the use of radial, axial, and mixed cooling systems; formulation of the main assumptions for the three-dimensional ventilation and thermal calculation of the bulb hydrogenerator; carrying out a three-dimensional calculation for a hydrogenerator with axial ventilation; determining airflow speeds in the channels and temperatures of active parts of the hydrogenerator under the conditions of using discharge fans and without them; carrying out a three
Tretiak, OleksiiArefieva, MariiaMakarov, PavloSerhiienko, SerhiiZhukov, AntonShulga, IrynaPenkovska, NataliiaKravchenko, StanislavKovryga, Anton
The substantial growth of power converters in electric vehicles necessitates more energy consumption and, as a result, greater heat generation. To avoid the power converter’s excessive heat, an innovative curved microchannel with diamond-shaped and pentagonal cross-sections was developed. The flow and heat transfer characteristics of the Gc3N4/Water (0.3%), Al2O3/Water (0.3%), and Al2O3-Gc3N4/Water (0.3%) hybrid nanofluid were assessed. The experimental investigation was carried out by different mass flow rates of about 0.1 to 0.5 LPM under a uniform heat flux of 50 kW/m2. The heat sink had a cross-sectional area of 80×48mm2. In comparison to the diamond channel heat sink through hybrid nanofluids, findings from experiments resulted that the heat transfer rate and pressure drop for the diamond channel enhanced by 14.2% and 18.9%, respectively. In comparison to Gc3N4/Water and Al2O3/Water nanofluids, the hybrid nanofluid improved the heat transfer rate for the diamond micro channel heat
R L, KrupakaranPetla, Ratna KamalaAnchupogu, PraveenKala, Lakshmi KGangula, Vidyasagar ReddyTarigonda, Hariprasad
There are various steering technologies are available in market nowadays. Hydraulic Power Steering (HPS) is one of them. As hydraulic name is linked to it the temperature role comes to play. While doing hard cornering the hydraulic oil used to assist the working in steering system get over heated, due to which oil loses its viscosity became one of the major causes of hard steer in trucks. Also, due to limited space the large heat exchanger cannot be used there. So, objective of this Thesis is to examine an effective solution which can be compact in design and at the same time should be effective to solve this problem. After going through literature analysis, we finalize that the Principal of Pulsating Heat Pipe could be a possible solution. So, for that we design different model based on previous research work in Creo and simulate them in Star CCM+ to finalize the optimality.
Saikrishna, VNLP, RudreshaYadav, SatyendraB, RuthvikaVishwasa, Viditha
With the rapid development of new energy vehicles, lithium-ion batteries (LIBs) have been widely used in the automotive sector. The performance and safety of LIBs in electric vehicles (EVs) are significantly influenced by operating temperature, making the development of an effective battery thermal management system (BTMS) crucial. In recent years, phase change material (PCM)-based BTMS technology has been recognized as one of the most promising solutions. Compared to traditional air and liquid cooling systems, PCM cooling technology exhibits superior cooling performance due to its large latent heat and efficient heat dissipation capabilities, while also eliminating the need for additional pump power consumption. Therefore, in-depth research on PCM cooling technology is of significant academic and practical value for enhancing the effectiveness and safety of power battery thermal management. This study investigates the effects of thermal conductivity, melting point, and thickness of
Lv, Kang-MinSu, Chu-QiWang, Yi-PingYuan, Xiao-HongLiu, Xun
Energy saving and emission reduction is an important part of the development of electric vehicle technology. Thermal management system affects vehicle energy consumption and carbon emissions, and it is necessary to develop the next generation of thermal management systems to replace R134a with high-performance and low GWP refrigerant. In this paper, a dual-side indirect heat pump system architecture was designed to be compatible with R290 and R134a refrigerants. According to the results of the system bench test, the cooling and heating performance of the R290 system was better than that of the R134a system, and the charge amount of R290 was no more than 150g, which was safe for vehicle application. Therefore, the R290 dual-side indirect heat pump system can be used as a feasible solution for the next-generation thermal management system.
Wang, ZhimingYin, XiangCao, Feng
The advancement of clean energy technology has resulted in the emergence of fuel cells as an efficient and environmentally friendly energy conversion device with a diverse range of potential applications, including those in the fields of transportation and power generation. Among the challenges facing fuel cell technology, thermal management represents a significant technical hurdle. The advancement of innovative thermal management methods and system design is imperative to address issues such as high waste heat. In light of the above, this paper presents a methodology for the application of fuel cell thermal management predictive control algorithms in engineering, with a particular focus on fuel cell engine systems that have been implemented in fuel cell cars. This paper proposes a thermal management control method based on a model predictive control algorithm for proton exchange membrane fuel cell systems. The objective of the methodology is to predict and adjust the thermal
Yu, ZhiyangDing, TianweiHuang, XingWang, YupengChen, Guodong
The thermal management system of fuel cells poses considerable challenges, particularly due to large time delays and nonlinear behaviors that complicate effective temperature control of the stack. In response to these challenges, this study introduces a novel fuel cell inlet temperature feedback control method based on the internal model principle, designed to enhance control accuracy. Simulations were conducted using MATLAB/Simulink® to evaluate the performance of both Proportional-Integral (PI) and internal model controllers through various tests, including step response and random condition assessments. The results demonstrated that the proposed internal model controller significantly outperformed traditional PID control in both static and dynamic scenarios. Specifically, during step response testing, the maximum temperature overshoot was minimized to just 1.5°C, with a steady-state error of less than 0.5°C. In dynamic performance testing, the inlet temperature exhibited a rapid
Liu, Shiguang
PEM electrolysis system has characteristic of excellent performance such as fast response, high electrolysis efficiency, compact design and wide adjustable power range. It provides a sustainable solution for the production of hydrogen, and is well suited to couple with renewable energy sources. In the development process of PEM electrolysis controller, this article originally applied the V-mode development process, including simulation modeling, RCP testing, and HIL testing, which can provide guidance in the practical application of electrolytic hydrogen production. In this paper, we present modeling and simulation study of PEM water electrolysis system. Model of electrolytic cell, hydrogen production subsystem and thermal management subsystem are constructed in Matlab/Simulink. Controller model was designed based on PI control strategy. A rapid prototyping controller with MPC5744 chip was used to develop the control system of electrolytic hydrogen production system. Hardware in the
Hua, YuweiJin, ZhenhuaTian, YingTao, Yuepeng
This paper proposes a method that speeds up the Model Predictive Control (MPC) algorithm in the thermal management system of air-cooled Proton Exchange Membrane Fuel Cell (PEMFC), with an integration of machine learning and Active Set Method (ASM) of quadratic programming. Firstly, the parameters of the electrochemical model and mass transfer model of PEMFC are identified by swarm intelligence algorithms such as particle swarm algorithm and bat algorithm, and a semi-empirical model that can simulate actual dynamics is established. Based on this, a model predictive controller based on Active Set Method (ASM) is designed, and the optimization solution algorithm is optimized to solve the problem of slow and poor real-time performance. Combined with machine learning methods such as K-nearest neighbor algorithm and support vector machine, the warm start of the optimization solution algorithm is realized to improve the solution efficiency. The results show that using the warm-start MPC
Lv, HangChen, FengxiangPei, Yaowang
The dynamic behavior of the water and thermal management are critical to stabilize the performance of the proton exchange membrane fuel cell (PEMFC) during severe load changes. In this paper, a fuel cell hybrid electric vehicle (FCHEV) dynamic simulation model is established to evaluate the changes in liquid water and temperature distribution inside the fuel cell stack under a vehicle driving cycle conditions. This paper focuses on analyzing the power generation performance of the stack and the dynamic behavior of internal water and heat transfer following the demand of the vehicle. According to the simulation results, the temperature of MEA and cooling water fluctuates greatly, but the temperature of MEA is always higher than the cooling water temperature by about 1.57 degrees Celsius (average value). Compared to the experimental measurements of temperature, the simulation error for the maximum temperature is 3.4% and the simulation error for the average temperature is 4.4%. The
Zhao, XiaojunShen, XuesongWang, YanboShi, WangyingYang, TaoShan, FengxiangMa, XiaoWang, XinZhang, YonghengPan, Fengwen
This paper addresses a series of issues in the thermal management system of proton exchange membrane fuel cells (PEMFC) during power fluctuations, such as slow system response, insufficient stability, significant temperature fluctuations, and the complexity of coupled control between coolant flow and air flow. A solution is proposed by designing separate Linear Active Disturbance Rejection Controllers (LADRC) for the coolant flow and air flow control loops. A one-dimensional model of the PEMFC thermal management system was established on the LMS AMESIM simulation platform, combined with a hydrogen fuel cell vehicle model and a driver model, fully considering various influencing factors such as vehicle power fluctuations and driver demands. Subsequently, the LADRC control algorithm was developed on the Matlab-Simulink platform, and a co-simulation analysis was performed to compare the control effects of PID control and LADRC under both custom operating conditions and the New European
Zhu, ShaopengMei, JingYang, LangZong, YajingLiu, YunmeiZhang, BoChen, Huipeng
The thermoelectric generator system is regarded as an advanced technology for recovering waste heat from automotive exhaust. To address the issue of uneven temperature distribution within the heat exchanger that limits the output performance of the system, this study designs a novel thermoelectric generation system integrated with turbulence enhancers. This configuration aims to enhance convective heat transfer at the rear end of the heat exchanger and improve overall temperature uniformity. A multiphysics coupled model is established to evaluate the impact of the turbulence enhancers on the system's temperature distribution and electrical output, comparing its performance with that of traditional systems. The findings indicate that the integration of turbulence enhancers significantly increases the heat transfer rate and temperature uniformity at the rear end of the heat exchanger. However, it also leads to an increase in exhaust back pressure, which negatively affects system
Chen, JieDing, RenkaiWang, RuochenLiu, WeiLuo, Ding
In cold environments, it is slow and risky for charging rate of electric heavy-duty trucks due to lithium plating. Common heating-charging methods overlook the complex dynamics between current, temperature, and battery aging, which need to be further improved. This study presents a tailored thermal management strategy for low-temperature battery charging, analyzing heating performance and battery improvement effect on the fast-charging performance. The data-driven multi-tiered power heating strategy based on a customer electro-thermal-aging model was proposed to minimize charging time and costs. The heating power combinations have been optimized by a particle swarm optimization algorithm, which outperforms conventional methods that aim to reach a set temperature. The optimized strategy reduced charging time by 11% and battery life degradation by only 0.0512%, enhanced the efficiency of cold-weather fast charging for electric trucks.
Lin, JieweiJiang, FeifanDai, HuweiSun, LeiLiu, BaoguoLi, ShiboZhang, Junhong
With the rapid adoption of new energy vehicles (NEVs), effective thermal management has become a crucial factor for enhancing performance, safety, and efficiency. This study investigates the steady-state and dynamic characteristics of a secondary loop CO₂ (R744) thermal management system designed for electric vehicles. The secondary loop system presents several benefits, such as improved safety through reduced refrigerant leakage and enhanced integration capabilities with existing vehicle subsystems. However, these advantages often come at the cost of decreased thermodynamic efficiency compared to direct systems. Experimental evaluations were conducted to understand the effects of varying coolant flow rates, discharge pressure, and dynamic startup behaviors. Results indicate that while the indirect system generally shows a lower coefficient of performance (COP) than direct systems, optimization of key parameters like coolant flow rate and discharge pressure can significantly enhance
Zong, ShuoHe, YifanGuan, YanDong, QiqiYin, XiangCao, Feng
To investigate the characteristics of a battery direct-cooling thermal management system integrated with the passenger compartment air-conditioning in a range-extended hybrid electric vehicle (REV), a model of the vehicle’s direct-cooling and liquid-cooling thermal management systems was established in GT-SUITE software. The findings are as follows: (1) Under high-temperature fast-charging conditions, the direct-cooling thermal management system exhibited improved performance indicators compared to the liquid-cooling system. Specifically, the charging time was reduced by 3.8%, the maximum heat exchange power increased by 27.33%, the battery temperature decreased by 2.37°C, the thermal decay rate was only 6%, and the average system energy efficiency ratio increased by 8.37%. (2)The outlet pressure of the direct-cooling plate significantly affected the temperature reduction of the battery pack during high-temperature fast-charging. The results indicated that within a certain range, a
Li, Li-JieSu, ChuqiWang, Yi-PingYuan, Xiao-HongLiu, Xun
With the popularity of electric vehicles, the application development of heat pump type automobile air conditioning system has been focused. Meanwhile, the traditional R134a needs to be replaced by more environmentally-friendly refrigerants under the Kigali Amendment. In this paper, a novel direct expansion heat pump air conditioning system with three circuit switching (DXACS) was proposed, and three low GWP refrigerants R1234yf, R1234ze(E) and R290 were carried out to evaluate the system performance. The results show that the winter range attenuation ratio of DXACS is 26.9%, significantly lower than the prototype EV360 (57.5%); the DXACS with R290 shows the best heating performance, COPh and qcv are 2.3% and 57.3% higher than R134a in extremely cold conditions, respectively. This study provides valuable insights for the development of efficient and green thermal management technology of new energy vehicles.
Zhu, TengfeiLiu, YeChen, Qinghua
The electric heavy-duty truck has been receiving much attention due to its low carbon emission characteristic. This paper presents the winterized design of thermal management for an electric heavy-duty truck. The changes of important parameters in the modes of rapid heating from a cold start battery, cabin defrosting, and cabin heating in winter are discussed based on water source heat pumps. It takes 1300 seconds to warm the battery to 5°C from an ambient temperature of -10°C. Under the same heat production condition, the proposed water source heat pump can save 28.2% energy comparing with the air source heat pump, the cabin air conditioner air outlet can stay above 40°C for more than 5 minutes, and the cabin temperature can be stabilized at 20°C to meet the heating demand of the crew in winter.
Yu, BoDai, HuweiLin, JieweiHan, FengJiang, FeifanZhang, Junhong
Thermal management system of electric vehicles (EVs) is critical for the vehicle's safety and stability. While maintaining the components within their optimal temperature ranges, it is also essential to reduce the energy consumption of thermal management system. Firstly, a kind of architecture for the integrated thermal management system (ITMS) is proposed, which can operate in multiple modes to meet various demands. Two typical operating modes for vehicle cooling in summer and heating in winter, which utilizes the residual heat from the electric drive system, are respectively introduced. The ITMS based on heat pump enables efficient heat transfer between different components. Subsequently, an ITMS model is developed, including subsystems such as the battery system, powertrain system, heat pump system and cabin system. The description of modeling process for each subsystem is provided in detail. The model is tested under world light vehicle test cycle (WLTC) condition of six different
Zhao, LuhaoTan, PiqiangYang, XiaomeiYao, ChaojieLiu, Xiang
A mathematical model of the thermal management system (TMS) for an extended-range hybrid electric vehicle is developed. The variation in engine coolant temperature is examined under different water pump and fan control strategies, and its subsequent impact on engine TMS energy consumption is analyzed. Based on the simulation results of energy consumption under various control parameters, machine learning regression models are constructed, and four different regression algorithms are applied. By incorporating temperature-based optimization into the water pump and fan control strategy, system energy consumption can be effectively reduced. The machine learning regression results indicate that the mathematical model of TMS cannot be simply regarded as a linear model. ANN and SVM regression show high degree of agreement with the mathematical model. This study provides a theoretical foundation for the development of data-driven tool for optimizing real-time TMS control strategies.
Pan, ShiyiZhang, NanZheng, JunliSun, TianfuZidi, Li
An effective vehicle integrated thermal management system (ITMS) is critical for the safe and efficient operation of proton exchange membrane fuel cell (PEMFC) vehicles. This paper takes a fuel cell vehicle (FCV) as the research object, comprehensively considers the vehicle layout environment and thermal management requirements, and designs a complete thermal management system for FCV. The key components are selected and designed to match the performance and the control strategy of ITMS of fuel cell vehicle is developed. To do that, the ITMS model is established based on the heating principle and heat transfer theory of each key component. Then, the ITMS under Worldwide Harmonized Light Vehicles Test Cycle (WLTC) operating conditions at different ambient temperatures are simulated and analyzed by selecting indicators such as coolant flow rate and temperature. Under the ambient temperature of 40°C, the temperature of PEMFC is basically stable between 78 °C and 83°C, the coolant outlet
Jiang, QiXiong, ShushengWang, YupengZhu, ShaopengChen, Huipeng
Magnesium oxide (MgO) nanofluids are of great interest for enhancing the performance in thermal management especially in automotive applications, where efforts have been made to reduce parasitic losses from traditional cooling systems. These findings highlight the effects of Water–ethylene glycol and MgO nanofluids on viscosity and thermal conductivity in specific filling a gap in research that allows to clarify how these states behave at different temperature (T) and concentration (C) conditions. Test results demonstrate that the thermal conductivity of MgO nanofluids improved adequately /while its corresponding change in viscosity remained under control, affirming a significant improvement for energy savings by means heat transfer enhancement using new generation coolants based on this nano-additive. The results also provide useful information for design and development of automotive cooling systems, including real numbers on performance improvements that lead to more efficient and
Jeyanthi, P.
The aim of the article is to evaluate the effect of the cooling system on the NVH behavior of traction permanent magnets synchronous motors (PMSMs). An effective numerical method is proposed for modeling the fluid–structure interaction in the cooling system of PMSMs. A simplified physical prototype of a cooling jacket of a PMSM is realized by welding two concentric tubes with an internal cavity filled by coolant. A finite element model of the structure is realized. The coolant is modeled as an acoustic domain to account for the fluid–structure interaction in the cavity and a coupled acoustic–structural dynamic problem is solved. The model is validated by experimental modal tests conducted on the prototype of the cooling jacket both with and without the presence of coolant. The validated model is employed to quantify the effect of the cooling system on a real PMSM. The structure of a 10-poles, 12-slots electric machine is modeled by means of finite element method. The model includes the
Barri, DarioSoresini, FedericoBallo, FedericoLucà, FrancescantonioManzoni, StefanoGobbi, MassimilianoMastinu, Giampiero
The comfort of seats increasingly becomes a crucial factor in the overall driving experience, particularly as vehicles become increasingly integrated into people’s daily lives. Passengers often maintain a relatively fixed posture and have close contact with the seat for extended periods of time, leading to issues such as heat, humidity, and stickiness. In order to enhance the thermal comfort experienced by occupants, manufacturers are no longer satisfied with ensuring the thermal comfort performance of vehicles only through the HVAC system in the cabin, but also developed a microclimate control seat that adjusts the temperature through ventilation between the contact surface of the seat and the human body, trying to improve the thermal comfort of passengers more effectively. However, the ventilation ducts of these seats are commonly designed based on empirical or autonomous standards, and their effectiveness is subsequently assessed through test or simulation, typically under unloaded
Zhang, TianmingRen, JindongZhang, Haonan
Mechanical component failure often heralds superficial damage indicators such as color alteration due to overheating, texture degradation like rusting or false brinelling, spalling, and crack propagation. Conventional damage assessment relies heavily on visual inspections performed by technicians, a practice bogged down by time constraints and the subjective nature of human error. This research paper delves into the integration of deep learning methodologies to revolutionize surface damage evaluation, addressing significant bottlenecks in diagnostic precision and processing efficiency. We detail the end-to-end process of developing an intelligent inspection system: selecting appropriate deep learning architectures, annotating datasets, implementing data augmentation, optimizing hyperparameters, and deploying the model for widespread user accessibility. Specifically, the paper highlights the customization and assessment of state-of-the-art models, including EfficientNet B7 for
Cury, RudonielGioria, GustavoChandrasekaran, Balaji
The research introduces the thermal properties of silicon dioxide (SiO2) nanofluids and the promising application of these fluids in hybrid vehicle cooling systems. How to make fluids is simply to disperse a 50-50 mixture of both Ethylene Glycol and Water; into this solution add SiO2 nanoparticles concentration ranges from 0.1% up to 0.5% volume according desired properties or material characteristics etc. When viscosities and thermal conductivities of nanofluid were measured over the temperature range from 25 to 120 °C using Brookfield viscometer and transient hot-wire method; results were as follows: Viscosity of SiO2 nanofluids at 120°C higher concentrations 0.5%, more viscous fluids, thermal conductivity also rose with results, although there was a plateau at around 40% increase compared to that of water-based slurries. At 0.5% concentration, thermal conductivity increased by up to 20% at 120 °C, compared with the value of pure ethylene glycol. These results suggest that SiO2
Sundaram, V.Madhu, S.Vidhyalakshmi, S.Saravanan, A.Manikandan, S.
This study investigates the influence of Silica-Diamond-Like Carbon (Si-DLC) coated pistons on performance metrics of diesel engine fuelled with various blends of Cassia Fistula biodiesel (CFBD10, CFBD20, CFBD30, and CFBD40). The primary focus is on key performance metrics, including Brake Thermal Efficiency (BTE), Brake Specific Energy Consumption (BSEC), and Exhaust Gas Temperature (EGT). The results demonstrated improvement in BTE and EGT, alongside a reduction in BSEC across all biodiesel blends compared to conventional diesel. Specifically, at full engine load, CFBD10 exhibited a BTE of 33.41%, which is 3.17% higher than neat diesel in the stock engine. At part load and no-load scenarios, improvements of 2% and 0.51% over neat diesel were recorded. During no-load conditions, the BSEC for CFBD10 was measured at 9.901 MJ.kW-hr, 0.738 MJ.kW-hr lower than that of neat diesel. Further increases in Cassia fistula blends resulted in higher BSEC values due to lower calorific content
Veeraraghavan, SakthimuruganDe Poures, Melvin VictorMadhu, S.Palani, Kumaran
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