Thermal Coupling Model Research Articles

Research on the Sealing Performance of Segmented Annular Seals Based on Fluid–Solid–Thermal Coupling Model

Research on the Sealing Performance of Segmented Annular Seals Based on Fluid–Solid–Thermal Coupling Model

Simulation study on the effect of palladium layer thickness and temperature on the bonding properties of palladium coated copper wire

Palladium coated copper (PCC) wire is an emerging bonding wire. There are relatively few studies on the effect of palladium plating thickness and temperature on its bonding performance. In order to investigate the effects of three parameters, namely palladium plating thickness, chip preheating temperature and the free air ball (FAB) initial temperature, on the bonding performance of PCC wires, this paper establishes a transient nonlinear finite element analysis model of thermal coupling between bare copper wires and PCC wires, and simplifies the whole bonding process into two stages of impact and ultrasonic vibration to carry out the experimental simulation. Firstly, the Taguchi orthogonal test method was adopted to obtain the ranking of the degree of influence of the three factors on the bonding results, and the optimum palladium plating thickness and FAB initial temperature of 100 nm and 100 °C were derived, respectively. Then the PCC wires with 100 nm palladium plating thickness were selected, and the bare copper wires were used as the reference, and multiple one-factor simulation experiments were carried out under the condition of changing the chip preheating temperature only. The simulation results show that the FAB and pad stress levels in the bonding results of the PCC wires are significantly higher than those of the bare copper wires, but the GaN layer stress is less than that of the bare copper wires. Moreover, there is an approximate parabolic relationship between the maximum stresses of pad and GaN layer and the preheating temperature of the chip. In the bonding results of bare copper wire, there is also an approximate parabolic relationship between the maximum stress of FAB and the chip preheating temperature. This parabolic relationship allows a prediction of the optimum chip preheating temperature. Selecting the appropriate palladium plating thickness and controlling the appropriate FAB temperature and chip preheating temperature can improve the bonding quality, and this numerical simulation work can provide a reference for the selection of palladium plating thickness and temperature parameter regulation of PCC wires.

Optimization method for geometric shape of DC GIL insulators based on electric thermal multi-physics field coupling model

Optimization method for geometric shape of DC GIL insulators based on electric thermal multi-physics field coupling model

Cumulative thermal coupling modeling and analysis of oil-immersed motor-pump assembly for electro–hydrostatic actuator

The Electro–Hydrostatic Actuator (EHA) is applied to drive the control surface in flight control system of more electric aircraft. In EHA, the Oil-Immersed Motor Pump (OMP) serves as the core as a power assembly. However, the compact integration of the OMP presents challenges in efficiently dissipating internal heat, leading to a performance degradation of the EHA due to elevated temperatures. Therefore, accurately modeling and predicting the internal thermal dynamics of the OMP hold considerable significance for monitoring the operational condition of the EHA. In view of this, a modeling method considering cumulative thermal coupling was hereby proposed. Based on the proposed method, the thermal models of the motor and the pump were established, taking into account heat accumulation and transfer. Taking the leakage oil as the heat coupling point between the motor and the pump, the dynamic thermal coupling model of the OMP was developed, with the thermal characteristics of the oil considered. Additionally, the comparative experiments were conducted to illustrate the efficiency of the proposed model. The experimental results demonstrate that the proposed dynamic thermal coupling model accurately captured the thermal behavior of OMP, outperforming the static thermal parameter model. Overall, this advancement is crucial for effectively monitoring the health of EHA and ensuring flight safety.

Simulation on lightning erosion protection performance of CFRP laminates with metal cluster structure

The tufting technology has the advantages of high flexibility and high economy. Research has found that metal tufting structures can significantly improve the mechanical and electrical properties of carbon fiber composites, and have great prospects in engineering applications. In order to investigate the damage characteristics of carbon fiber CFRP laminates with metal tufted structures during lightning strikes and the influence of structural parameters on lightning protection effectiveness, an electric thermal coupling model of CFRP laminates with metal tufted structures was established. Comparing the simulation and experimental results under the same load condition, it was found that the two were consistent in terms of damage appearance, damage area, and damage propagation trend, proving the effectiveness of the model. The transverse heat transfer process and current conduction path of CFRP laminates with metal cluster structure were discussed. The research results indicate that the ablation surface area of CFRP laminates with metal tufted structures is reduced to 8.06% of the reference component. Wire spacing had an effect on the area and shape of the area of the high potential region, and the wire spacing had the greatest impact on the ablation area of lightning strikes.

Investigation on electromagnetic and heat transfer coupling of heating susceptor for selective microwave hybrid soldering: 3D multi-physics simulation and experiment

The utilization of microwave hybrid heating as an emerging technique in the field of low-temperature joining presents a notable benefit of delivering both selective and rapid heating, a feature that is not commonly observed in traditional soldering methods. However, due to the complex multi-physical coupling problem, the factors and mechanisms affecting the heating effect of the susceptors have not been clearly explained. To examine the effect of susceptor shape, size, and process parameters on heating efficiency, a numerical model of electromagnetic and thermal coupling was created to analyze silicon carbide susceptor heating under microwave action. The response surface method examined how microwave frequency, power, and exposure time affect susceptor heating efficiency. The model’s three process parameters are used to selectively heat Cu/SAC305/Cu joints, and the connection mechanism is studied. The results reveal that cylindrical susceptors heat more efficiently and uniformly than cubic ones. The heating efficiency is the highest when the height of the susceptor is 30 mm. Moreover, the heating effect is optimum at 2.45 GHz. Microwave power and exposure period positively linked with susceptor heating efficiency. The finite element simulation model shows that energy consumption at 2.45 GHz\\2 kW210 s is 78.38 % of that at 2.45 GHZ\\1 kW370 s, and the maximum temperature difference is 73.44 % of that at 2.45 GHz\\3k W\\90 s. MHS experiments show that as exposure duration increases, Cu6Sn5 grew and the growth orientation becomes consistent and perpendicular to the {0 0 0 1} family of crystal planes. Under process settings of 2.45 GHz \\ 2 kW \\ 210 s, the joint can achieve 16.55 MPa shear tensile strength. The results can serve as references for the study on selective microwave hybrid soldering and provide a new idea for selective and efficient soldering.

Research on the Optimization of the Heating Effect of Lithium-Ion Batteries at a Low Temperature Based on an Electromagnetic Induction Heating System

Based on an electromagnetic induction heating system that was recently developed in a previous work, an orthogonal test with three elements and nine levels was carried out to improve the heating effect of the system. This was intended to achieve a balance between the heating rate and temperature uniformity, where the electrochemical and thermal behaviors of the heated lithium-ion battery could be characterized by a high-accuracy electrochemical–thermal coupling model. This was validated against constant-current discharge and HPPC test data at room temperature and different low temperatures. Under the optimal parameter combination that was found in the orthogonal test, the battery temperature could rise to 293.15 K from 243.15 K in 494 s, with a maximum temperature rise rate of 0.133 K·s−1. The temperature difference after heating reached 4.21 K, which resulted from the heat conductivity of the battery material due to the skin depth of the battery shell and the material properties inside the battery. Due to the internal resistance, which decreased to no more than a quarter of the low-temperature level, both the usable energy and pulse power were increased more than 2.5 and 3 times, respectively. The enhancement of the energy output ability could provide a greater cruise range and improved dynamics for electric vehicles. The capacity calibration results obtained during the heating cycles indicated that there was only a 3.61% reduction in capacity retention after 120 repetitive heating cycles, which was 0.008 Ah below the normal cycle at 293.15 K, even compared with room-temperature capacity calibration, thus reducing the effect on the battery’s lifetime. Therefore, the electromagnetic induction heating system with a heating strategy could achieve a beneficial compromise between the temperature rise behavior, cycle lifetime, and working ability, indicating considerable potential for the optimization of the heating effect.

Research on charging monitoring method for lithium-ion batteries based on magnetic field sensing

With the rapid and continuous development of new energy vehicles, safety issues during charging have become increasingly prominent. Thus, there is an urgent need to strengthen charging safety management. However, current charging detection methods have limitations, such as difficulty in monitoring local battery pack currents, and indirect monitoring through temperature and gas sensors lead to lag. To address these limitations, this article proposes a safety monitoring method based on an improved lithium-ion battery magnetic field sensing model that covers the entire charging process. Specifically, thermal field analysis was introduced to the existing electric magnetic coupling model, resulting in an electric thermal magnetic multi-physical field coupling model. By conducting experiments, the study verified that the accuracy of the improved model has increased by 15.5 %. Based on this model, the study proposed a method for predicting and warning of abnormal currents using BP neural network and mathematical statistical laws. The results showed that the current prediction accuracy of this method reached 96.4 %. Such high accuracy ensures real-time comprehensive monitoring of the current information of lithium-ion battery packs, thereby eliminating the hidden dangers of charging safety accidents caused by the lack of local current detection.

Design and Performance Analysis of a Composite Thermal Protection Structure for a Robot Pan–Tilt

To improve the adaptability of the robot pan–tilt to the high-temperature environment, a design scheme for a composite thermal protection structure composed of aerogel felt, hollow glass, and skin is proposed. The effects of aerogel felt thickness, glass type, and ambient temperature on the thermal protection performance of the structure are studied, using a fluid–solid–thermal coupling model. Numerical results show that the structure exhibits good protection performance, and that the thermal resistance distribution changes the main path of heat transmission. The optimal thickness of the aerogel felt is approximately 8 mm. Compared to 3 mm, 5 mm, and 10 mm thicknesses, 8 mm reduces the maximum temperature by 15.90%, 8.37%, and 6.22%, and reduces the total entropy by 79.23%, 52.44%, and 12.5%. Lower thermal conductivity of the gas inside the hollow glass results in decreased maximum temperatures and total entropy. Using argon-filled hollow glass at 573.15 K decreases maximum temperature by 33.52% and 8.40%, with a total entropy reduction of 33.46% and 6.04%, compared to the single-layer and air-filled glass. Higher ambient temperatures correlate with increased maximum temperature, total entropy, and average surface-heat-transfer coefficient, indicating that the adaptability of the structure to high-temperature environments is limited.

Heat dissipation performance research of battery modules based on composite phase change materials cooling and electrochemical thermal coupling model

In order to improve electric vehicle lithium-ion batteries (LIBs) performance and increase cycle life, it is crucial to design a reliable and efficient battery thermal management system (BTMS). Compared with other active battery cooling methods, passive phase change material (PCM) cooling has the advantages of simple structure, good temperature control uniformity, strong reliability, and no additional energy consumption. This article uses a series of experimental procedures to add expanded graphite to traditional paraffin wax PCM and obtain composite phase change materials (CPCM) with different mixing ratios. A control experiment is created to compare the cooling performance of the CPCM cooling with natural convection cooling, research shows that the cooling performance of CPCM can well meet the cooling demand which maximum temperature and maximum temperature difference of battery modules. In addition, to study the performance of thermal properties parameters related to CPCM, a COMSOL numerical calculation model of battery module based on CPCM cooling and electrochemical thermal coupling model is established. The effectiveness and accuracy of the model are verified through heat generation experiments at different rates (0.5 C, 1 C, 1.5 C), with a maximum temperature error of 1.6 K and an error accuracy of less than 0.6%. Subsequently, the performance of phase change temperature, thermal conductivity and phase change latent heat is studied and reasonable value ranges are obtained, which are 312 K∼318 K, 2.5 W /(m·K), and 175 J/g∼200 J/g, respectively.

Numerical Modeling of Dynamic Thermal Coupling in GaN HEMTs Calibrated by Transient Measurements

Numerical Modeling of Dynamic Thermal Coupling in GaN HEMTs Calibrated by Transient Measurements

Numerical Study on Heat Generation Characteristics of Charge and Discharge Cycle of the Lithium-Ion Battery

Lithium-ion batteries are the backbone of novel energy vehicles and ultimately contribute to a more sustainable and environmentally friendly transportation system. Taking a 5 Ah ternary lithium-ion battery as an example, a two-dimensional axisymmetric electrochemical–thermal coupling model is developed via COMSOL Multiphysics 6.0 in this study and then is validated with the experimental data. The proportion of different types of heat generation in a 26,650 ternary lithium-ion battery during the charge/discharge cycle is investigated numerically. Moreover, the impact of essential factors such as charge/discharge multiplier and ambient temperature on the reaction heat, ohmic heat, and polarization heat are analyzed separately. The numerical results indicate that the total heat generated by the constant discharge process is the highest in the charging and discharging cycle of a single battery. The maximum heat production per unit volume is 67,446.99 W/m3 at 2 C multiplier discharge. Furthermore, the polarization heat presents the highest percentage in the charge/discharge cycle, reaching up to 58.18% at 0 C and 1 C multiplier discharge. In a high-rate discharge, the proportion of the reaction heat decreases from 34.31% to 12.39% as the discharge rate increases from 0.5 C to 2 C. As the discharge rate rises and the ambient temperature falls, the maximum temperature increase of the single-cell battery also rises, with a more pronounced impact compared to increasing the discharge rate.

Mapping the relationship between the temperature gradient of CRTS Ⅲ slab track on bridge and rail deformation in high-speed railways

Temperature gradient is an important factor affecting the periodic rail deformation of CRTS Ⅲ and the running stability of high-speed trains. The Comprehensive Empirical Mode Decomposition with Adaptive Noise (CEEMDAN) method is employed for the analysis of test data in site from CRTS III slab tracks on high-speed railway bridges. The correctness of the coupling model has been validated through data on-site. To analyze the mapping relationship between the temperature gradient of the CRTS Ⅲ slab track on the bridge and rail deformation in high-speed railways, a rail-slab track-bridge thermal coupling model was established, and the rail deformation distribution characteristics of the slab track on the bridge under the complex temperature gradient load were calculated. Furthermore, a prediction model of rail deformation under the action of the complex temperature gradient was proposed. The study results showed that the intrinsic mode function (IMF) decomposed by the CEEMDAN method reflects the sensitive wavelength of track irregularity and quantitatively describes the corresponding relationship between amplitude and seasonal temperature. In the measured data, the maximum amplitude of rail deformation caused by temperature differences in different seasons was 1.99 mm, reflecting the significant impact of temperature gradient on the additional track irregularities on the bridge. Under the action of the temperature gradient, the rail deformation of CRTS Ⅲ slab track on the bridge is the superposition of periodic sinusoidal fluctuation of the track and parabolic fluctuation of the simply supported beam. This study could provide a new method for predicting rail deformation and controlling track smoothness, so as to improve the stability and operation efficiency of trains.

Optimizing Extreme Fast Charging Strategy for Lithium-Ion Batteries: A Model Predictive Control Approach

With the increasing demand for extreme fast charging (XFC) in electric vehicles (EVs), there is an urgent need to develop health-conscious fast charging strategies for lithium-ion batteries. However, simply increasing the charging current can disproportionately accelerate battery aging, resulting in severe capacity and performance loss, while posing unacceptable safety risks during operation. In addition, the battery management system (BMS) needs to know the state of each cell for reliable and accurate management, but this involves significant computational burden. In other words, new fast charging strategies need to be developed to solve the dilemma between charging rate, battery aging, and computational complexity.In this work, we propose a novel framework for modelling, estimating, and balancing different types of state heterogeneities in a multi-cell battery module. This framework facilitates the development of optimal fast charging strategies based on battery electrochemical models and model predictive control (MPC). First, an electrochemical and thermal coupling model is formulated at the unit cell level, and a module model is formulated at the system level, taking into account various factors such as connection resistances and system terminals. Then, a non-linear MPC is used to achieve fast charging while considering the health of the battery module. Battery performance is tracked by accurately estimating the battery's internal state, which can support the balancing of all state heterogeneity types represented in the model by controlling the charging current according to the internal state. The proposed framework has three main advantages: (1) The modelling strategy has a flexible and configurable structure that can be applied to battery modules of any size. Using this, (2) the internal state of the battery can be estimated with reduced computational complexity. (3) MPC can be applied to cell-to-cell balancing and XFC strategy. The results of the proposed method provide important insights for achieving XFC and show promise for real-time online estimation and control. Figure 1

Lifetime Prediction of Aviation Cables Based on an Improved Electromagnetic–Thermal Coupling Model

Lifetime Prediction of Aviation Cables Based on an Improved Electromagnetic–Thermal Coupling Model

Research on thermal stratification of surge line in the marine reactor based on fluid-solid thermal coupling model

Due to the requirements of ship movement, the power of the marine reactor is constantly changing, and the expansion and contraction of the primary coolant make the fluid flow in and out through the surge line. This paper establishes a fluid-solid thermal coupling model for the thermal stratification of a Marine reactor surge line. The low Reynolds number eddy viscosity model and the curvature modification of the bending pipe are used in this model. Qiao experiment is provided to verify the model's applicability to the thermal stratification analysis. The typical working conditions of the Marine reactor are analyzed, and the results show that: the temperature difference between the top and bottom of the pipe changes constantly with the fluctuation of the fluid, the maximum temperature difference in the horizontal section is 59.6 K, and the maximum temperature difference in the vertical area is 23.9 K. The maximum stress fluctuation of the horizontal section is 36 MPa, while that of the vertical section is 5 MPa. In the non-destructive testing, many small pits were found in the horizontal section of the pipeline, while no obvious damage was found on the surface of the vertical section, which is consistent with the results of our numerical analysis.

Research on the Improvement of Lithium-Ion Battery Performance at Low Temperatures Based on Electromagnetic Induction Heating Technology

As the major power source for electric vehicles (EVs), lithium-ion batteries (LiBs) suffer from the degradation of technical performance and safety at low temperatures, which restricts the popularization of EVs in frigid regions. Thus, this study developed an extremely fast electromagnetic induction heating system in order to improve the poor performance of LiBs in cold weather. An electrochemical–thermal coupling model (ETCM), validated against the experimental results of charge and discharge, which successfully predicted LiB voltage, temperature, and other physical characteristics at various ambient temperatures, was established in COMSOL Multiphysics 6.0 as a development tool for evaluating the heating effect of the system. When the copper coil is subjected to a SAC (sinusoidal alternating current) of 8 A and 50 Hz, the LiB can be heated from 243.15 to 293.15 K within 6 min with an instantaneous temperature increase rate of 0.263 K/s and a homogeneous temperature distribution. The results of the capacity calibration, cyclable lithium detection, and HPPC simulation show that the heating method can visibly increase the Li+ concentration inside the active particle, and there was only a tiny concentration gradient on the surface of the particle. In addition, the internal resistance was approximately a quarter of that without heating; therefore, both the discharge energy and specific power boost were two times higher than the original level. Compared to the normal charge–discharge cycles at 293.15 K, the capacity retention of the LiB only decreased by 0.23% after 60 consecutive heating cycles, so the heating method can balance the temperature rise, work capacity, and LiB health. Furthermore, the improvements in the thermal insulation condition and material thermal conductivity are two feasible ways to optimize the temperature-increase effect.

Experimental and Simulation Studies on the Thermal Characteristics of Large‐Capacity Square Lithium‐Ion Batteries with Low‐Temperature Discharge

As the capacity of lithium‐ion batteries decays severely at low temperatures, it is important to study the electrochemical and thermal properties of lithium‐ion batteries at low temperatures. Herein, a large‐capacity prismatic lithium‐ion battery is selected to carry out experiments to study the electrothermal characteristics of the battery in different temperatures (25, 0, −10, and −20 °C). Second, a pseudo‐3D electrochemical–thermal coupling model is established and the validity of the model is verified. Finally, this article analyzes the influence of ambient temperature on the thermal characteristics of the battery during discharge. The results show that the battery discharge capacity gradually decreases with the decrease in the ambient temperature. At −20 °C, the discharged electricity is 66.51% of that at room temperature. At the same time, as the ambient temperature drops, the temperature rise on the surface of the battery increases during the discharge process, and at −20 °C, the temperature rise can reach 3.86 times than that at normal temperature. In addition, the change in reversible heat percentage is negatively correlated with the discharge rate and positively correlated with the battery temperature, while the effect of the discharge rate on irreversible heat is greater than that of ambient temperature.

Experimental and numerical investigations of induction heating for Ti-6Al-4V sheets and epoxy/carbon fiber composite laminates

The objective of this study is to present the electromagnetic and the thermal multi-field coupling model of the induction heating process for numerical simulation based on the finite element method. One of the most important difficulties encountered in the induction heating processes is to ensure homogeneous temperature distribution throughout the part. To improve the uniform temperature distribution in the sheet, the induction heating system is modelled with the ANSYS software taking into account some operational and geometrical parameters including current density and coupling distance between induction coil and sheet. Induction heating simulations were performed for all simulations at 20 kHz frequency ANSYS Maxwell. The numerical model has been verified by the conducted experiments for Ti6Al4V at the current of 50 A, 125 A, and 200 A, and the 1 mm and 3 mm gap distances. The relative error of the maximum temperature between the experiment and simulation was found around 14 % recorded at 25 s measurements. In addition, the effects of the current and the frequencies on the induction heating were evaluated by the verified numerical model for epoxy/carbon fiber (UD prepreg) and epoxy/carbon fiber (Woven prepreg) plates. The results show that the induction heating model is suitable and efficient to determine the temperature distribution within the thin plates by the finite element method.

Optimizing the Layout of a Ground Source Heat Pump System with a Groundwater–Thermal Coupling Model

Optimizing the Layout of a Ground Source Heat Pump System with a Groundwater–Thermal Coupling Model