Search Results (57)

As the demand for lightweight and high-performance conductive materials grows in power transmission systems, aluminum alloy rods have emerged as a cost-effective and scalable alternative to copper conductors. This review systematically examines the development status and technological progress in the purification and casting–rolling processes used in the production of Electrical Round Aluminum Rods (ERARs). It explores current challenges in improving electrical conductivity and mechanical strength while addressing issues such as hydrogen and oxide inclusion removal, grain refinement, and impurity segregation. Key purification techniques—including flux refining, gas treatment, filtration, and rotary injection—are compared in terms of performance, cost, and environmental impact. The paper also analyzes different casting–rolling methods, including continuous casting and rolling, twin-roll casting, and extrusion processes, with attention to process optimization and equipment design. Furthermore, emerging applications of artificial intelligence (AI) in predictive modeling, defect detection, and process parameter optimization are highlighted, offering a novel perspective on intelligent and sustainable ERAR production. This paper aims to provide insights for facilitating the industrial-scale production and performance enhancement of ERAR materials. Full article

Epoxy resin paper-impregnated bushings, as critical insulating components in power transformers, are subjected to complex electric fields, thermal fields, and mechanical stresses over extended periods. Their performance stability is directly linked to the safe operation of transformers. Given the significant costs associated with their production, reliability verification is a crucial aspect of their design and manufacturing process. This study employs the finite element simulation technology to systematically investigate the electric field distribution characteristics, thermal field distribution characteristics, and seismic performance reliability verification methods of epoxy resin paper-impregnated bushings. The simulation and calculation results indicate that for bushings with rated voltages of 40.5 kV, 72.5 kV, and 126 kV, the maximum radial electric field strengths are 1.38 kV/mm, 2.74 kV/mm, and 3.0 kV/mm, respectively, with axial electric field strengths all below allowable values. The insulation margin meets the 1.5 standard requirements. Under short-circuit conditions, the thermal stability analysis of the bushings reveals that the final conductor temperatures are all below 180 °C, indicating sufficient safety margins. All three types of bushings comply with the design requirements for an 8-degree earthquake intensity and are capable of effectively withstanding seismic loads. This research provides a theoretical foundation for the development and application of epoxy resin paper-impregnated bushings, offering a significant engineering application value in enhancing the safety and stability of transformers and power systems. Full article

Efficient coal grinding is a crucial aspect of the energy and mining industries. However, traditional grinding methods are known to be energy-intensive and cause significant wear on equipment as well as negative environmental impacts due to the release of small particles that can harm air quality and affect human health. In response to these challenges, we are conducting research to develop an electric pulse device for coal grinding. This device will use high-voltage discharges in a liquid medium to create shock waves that selectively destroy coal particles while minimizing mechanical damage. The electric pulse installation consisted of a control unit (for monitoring the operating modes of the installation), a generator (for converting the AC input voltage into DC output voltage), a capacitor (for energy storage), a protection system (for shutting down the installation in cases when a voltage exceeding the set safe operating discharge voltage occurs on the capacitor), a spark gap (forming a gap consisting of two conductive hemispherical electrodes separated by an air gap, designed to form an electric spark between conductors), and an electric pulse grinding device. The input material for each experiment had consistent parameters: the coal particles were diameter 8–10 mm and weighed 400 g. Coal was processed using the electric pulse method with various voltage values, numbers of pulses, capacitor capacities, and pulse frequencies. The yield of the final product depended on these parameters, and effective settings for producing coal powder were identified. The research results demonstrate that a flat metal mesh plate is effective as the negative electrode in the electric pulse grinding device. Full article

A PCB stator axial flux permanent magnet (AFPM) motor is presented that overcomes the manufacturing challenges associated with the complex geometry of conventional stators by employing a PCB substrate. Traditionally, AFPM motors are produced by winding coils around the stator teeth, a process that requires specialized winding machinery and is both labor intensive and time consuming, ultimately incurring considerable manufacturing costs and delays. In contrast, PCB substrates offer significant advantages in manufacturability and mass production, effectively resolving these issues. Furthermore, the primary material used in PCB substrates, FR-4, exhibits a permeability similar to that of air, resulting in negligible electromagnetic cogging torque. Cogging torque arises from the attraction between permanent magnets and stator teeth, creating forces that interfere with motor rotation and generate unwanted vibration, noise, and potential mechanical collisions between the rotor and stator. In the PCB stator design, the conventional PCB circuit pattern is replaced by the motor’s coil configuration, and the absence of stator teeth eliminates these interference issues. Consequently, a slotless motor configuration with minimal vibration and noise is achieved. The PCB AFPM motor has been applied to a vehicle-mounted electric water pump (EWP), where mass production and space efficiency are critical. In an EWP, which integrates the impeller with the motor, it is essential that vibrations are minimized since excessive vibration could compromise impeller operation and, due to fluid resistance, require high power input. Moreover, the AFPM configuration facilitates higher torque generation compared to a conventional radial flux permanent magnet synchronous motor (RFPM). In a slotless AFPM motor, the absence of stator teeth prevents core flux saturation, thereby further enhancing torque performance. AC losses occur in the conductors as a result of the magnetic flux produced by the permanent magnets, and similar losses arise within the PCB circuits. Therefore, an optimized PCB circuit design is essential to reduce these losses. The Constant Trace Conductor (CTC) PCB circuit design process is proposed as a viable solution to mitigate AC losses. A 3D finite element analysis (3D FEA) model was developed, analyzed, fabricated, and validated to verify the proposed solution. Full article

Nowadays, electric motors are an integral part of most modern electromechanical systems that are used in industry. It follows that industrial processes are becoming more dependent on their efficiency. If faults in electric motors are not rectified, they can lead to malfunctions and accidents, as well as production downtime. Symmetry of a three-phase system means that the voltage and current in the three phase conductors are equal to each other, with a period of 120°. Asymmetry occurs if one of these conditions or both conditions are violated at the same time. In most cases, asymmetry is caused by loads. Predictive diagnostics is the most effective way to identify motor faults while the motor is in operation and prevent the likelihood of failure. Predictive diagnostics can identify problems that could lead to major failures, thus reducing production downtime and maintenance costs. The paper discusses the control and diagnosis of electric motors using prediction techniques. In particular, the use of neural network models and predictive control to improve accuracy and reliability is investigated. The main objective of this research is to develop a neural network controller based on predictive model predictive control (MPC), which will improve the quality of the control and diagnostics system of electric motors, ensuring their stability and preventing possible malfunctions. Full article

Inductive Power Transfer (IPT) is evolving fast in many domains, but its efficiency, its extensive resource requirements, and its cost remain crucial problems for its development. Although the inverter is mainly responsible for its cost and material consumption, a considerable quantity of conductors is required for the coupling realization. Therefore, A drastic cost reduction is possible when comparing the traditional most efficient copper Litz wire with aluminum conductors for a similar volume and a lighter embedded system. However, alternative ribbon wire solutions are also characterized and seem promising as substitutes for such applications. First, standard electrical efficiency is evaluated for all cases, before the price and weight. To complement the results and as the alternative couplers imply different materials and production processes, a Life Cycle Assessment is performed. A comparison is carried out on copper and aluminum litz wires and copper and aluminum ribbons. Results demonstrate the promising interest in industrial application of such study, furthermore for systems requiring many couplers as Dynamic IPT (DIPT). Full article

High-current-carrying capability with minimum thermal elongation is one of the key reasons for using high-temperature low-sag (HTLS) conductors in modern power systems. However, their higher operational temperature can significantly affect corona discharge characteristics. Corona is one of the key factors in transmission line design considerations. Corona discharge is the leading cause of audible noise, radio interference, and corona loss in power transmission systems. The influence of conductor temperature on corona discharge characteristics is investigated in this paper using experimental methods and computational simulations. A simulation framework has been developed in COMSOL Multiphysics using the physics of plasmas and electrostatics to simulate corona plasma dynamic behavior and electric field distribution. The results show that the conductor temperature enhances the ionization by electron impact, enhances the production of positive and negative ions, changes the electric field distribution, and increases the electron temperature. This analysis emphasizes that temperature-dependent conditions affect the inception and intensity of corona discharge. Additionally, an experimental model was developed to evaluate corona voltage–current characteristics under varying temperature conditions. The study presents both simulation results and a newly developed model for predicting corona current at high conductor temperatures. Full article

The present paper is dedicated to the search for an alternative material based on an aluminum (Al)—few-layer graphene (FLG) composite for use in electrical applications. Due to its excellent properties, graphene has the potential for use in many applications, especially in electronics, electrical engineering, aerospace, and the automotive industry. One area where the properties of graphene can be exploited is in overhead power transmission, where the main challenge at the moment is to reduce transmission losses. The utilization of conductors that exhibit superior electrical conductivity is instrumental in ensuring the mitigation of transmission losses. The utilization of graphene or other carbon allotropes is appealing due to their elevated electrical conductivity, substantial mechanical strength, and considerable heat resistance, which can enhance the properties of the composite, thereby increasing its resistance to operational conditions, particularly long-term exposure to temperature, a parameter closely related to the current carrying capacity of the OHL. This article presents the findings of research on the production of a composite based on aluminum powder and graphene, as well as the identification of its electrical and mechanical properties. The primary challenge in this research lies in the development of a method to synthesize carbon materials with aluminum using powder metallurgy, with particular attention paid to the mixing and compacting process, which is of significant importance in ensuring the appropriate distribution of carbon material in the composite. The research carried out has determined the influence of the graphene content (0.1–1 wt.%) on the electrical conductivity (max. 35.4 MS/m) and mechanical properties of Al-FLG composites (UTS = 156 MPa). Full article

The electric field of transmission lines has serious negative impacts on residents’ production and life with the expansion of high voltage engineering. In order to study the influence of trees on the electric field of ultra-high voltage transmission lines, this paper conducted three-dimensional simulation calculations of the power frequency electric field of transmission lines based on the tree quantity and distribution. Firstly, in order to study the pattern of electric field strength distribution in transmission lines, the electric field strengths of transmission lines of different voltage levels were compared; the maximum-power-frequency electric field intensity of ultra-high voltage transmission lines occurs below the edge conductor. Secondly, by changing the number of trees, it was concluded that the electric field strength below the edge conductor gradually decreases with the number of trees. Finally, the maximum electric field strength value at 1.5 m below the edge conductor and the width of the transmission corridor decreased by changing the layout of the trees. The results show that studying the impact of a tree’s electromagnetic parameters on the power frequency electric field strength under transmission lines can help reduce the electric field strength and decrease the width of transmission corridors, which is of great significance for line design and cost savings. Full article

In recent years, the scientific and industrial interest regarding alternative technologies for transmission cables has increased. These conductors should efficiently transmit significant amounts of power between grid nodes, which are expected to be particularly congested due to the projected global increase in electricity production. Superconducting cables are considered a promising solution in this context, offering the potential to transmit large amounts of energy with minimal losses and compact dimensions, thereby potentially benefiting the environment. To evaluate the feasibility of integrating superconducting cables into existing grids, techno-economic approaches should be adopted. Such techniques enable the conceptual design of a specific cable structure, allowing users to explore a wide range of operating parameters to derive optimal designs. This paper reports a comprehensive techno-economic analysis of High Voltage Alternating Current (HVAC) cables realized with High-Temperature Superconducting (HTS) tapes, with the aim to transmit extremely high-power level. The optimal coaxial design is selected using Optimization Tool for Superconducting Cable Research (OSCaR) by implementing a graded approach to the critical current of the HTS tapes used for the different phases. This optimization aims to achieve the most effective balance between the cost of the coated conductors and their electrical properties. The whole set of model equations, the user-defined parameters, and the applied constraints are detailed. The OSCaR tool is then applied to assess the impact on the optimized design of the cable system and the corresponding cost indexes of several crucial parameters, such as the maximum transmitted power, the voltage level, and the line length. Full article

Constructing agricultural microbial gasification plants near livestock farms is essential for technical, economic, and environmental reasons. Utilising substrates from these farms allows for producing electricity, heat, and environmentally friendly manure. However, biogas plants often face technical challenges. This study evaluates the power quality of an agricultural biogas plant on a dairy farm. It was found that the plant was connected via a cable with an insufficient conductor cross-section, leading to significant voltage overshoots exceeding 14.6%, which prevented the activation of the second generator. Both generators could operate after replacing the feed-in cable, but considerable fluctuations in the feed-in voltage persisted. Further measurements indicated the need for changes in the digester design. Specifically, replacing the current two mixers with more lower-powered mixers operating alternately was proposed. Sharing these solutions more broadly can help prevent similar issues in future microbial gas plant constructions and optimise electricity production. Full article

This study presents issues related to electromagnetic pollution and the level of magnetic field radiation occurring around conductors used for electricity transmission and distribution. The fact that modeling and simulation are the most efficient methods of optimization, considering the cost–benefit ratio, was the premise of this work. This paper proposes the performance of a complex analysis, carried out in a comparative manner, which includes physical tests and simulations in the existing field around transmission and distribution cables used in transformer substations. In the first stage, the level of the magnetic field existing near the conductor carried by an electric current was tested (measured), and a virtual model was then designed to simulate the field in conditions similar to those of the test. The results obtained from the simulation were analyzed in comparison with those obtained by testing. The maximum permissible limits of exposure to an electromagnetic field, which are regulated by Government Decision HG 520/2016 of 20 July 2016 and Directive 2013/35/EU of the European Parliament and of the Council of 26 June 2013, were used as the reference to formulate conclusions for both situations considered. These comparisons were intended to determine the level of exposure to electromagnetic fields existing in places where electricity transmission/distribution conductors are located. Energy sustainability exists due to the versatile properties of the conductors, with the energy transmission and distribution network being functional regardless of the source of energy production. Full article

Recycling lithium-ion batteries provides sustainable raw materials. Crushing and separation are necessary for extracting metals, like lithium, from batteries. Crushing a battery carries a risk of fire or explosion. Fully discharging the battery is crucial for safe production. Discharging batteries in a salt solution is a simple and cost-effective large-scale process. However, it is important to note that there is a potential risk of corrosion and loss of battery elements when batteries are immersed in a salt solution. The purpose of this study is to investigate the effectiveness of two distinct methodologies at enhancing the voltage drop of a cylindrical battery when immersed in a salt solution while preventing corrosion. These techniques involve the application of iron and copper accelerators. A 20 wt.% salt water solution was chosen based on the research of several researchers. As the current flows through the metal parts, it encounters electrical resistance and forms an electric circuit with the electrolyte solution. This interaction converts electrical energy into various physical–electrical–electrochemical phenomena, leading to a decrease in battery voltage. Research revealed that the battery can be discharged up to 100% within 4 h without causing corrosion to its components. Another point to note is that if copper conductors are used, it is possible to decrease the battery voltage by around 90% within 8 h. The gap between the copper conductor and the battery had a direct impact on the battery’s discharge rate. Reducing the distance significantly increased the discharge rate, as confirmed by experimental evidence. This discharge mechanism was thoroughly described in a schematic, and, to further explain the electrochemical reaction, the Pourbaix diagram was utilized for both the Fe-Na-Cl and Cu-Na-Cl systems. Moreover, our theoretical predictions were validated through a chemical and mineralogical analysis of the precipitates that formed in the solution. Full article

The growth in the demand for electrical energy, which is driven by the constant growth of the metropolises and the expansion of the productive capacities of the industrial sector, entails the inevitable development of the electrical system to satisfy all the required demands in a convenient, efficient, and reliable manner. In this scenario, power distribution companies will continue to need to expand their electrical systems in the short and medium term to obtain the lowest investment and operating prices for the period considered in the analysis horizon. The expansion of the system can be projected statically or dynamically, which depends on the criteria that each distributor, in turn, applies in their expansion projects. Multi-criteria decision making can provide deeper analysis perspectives considering infinite possibilities for optimal network sizing and the technical, operational, quality of service, and even system reliability factors. This research proposes a multi-criteria decision technique based on the CRITIC method to determine the optimal design of an electrical distribution system. For this purpose, several design scenarios are defined with different types of electrical conductors, and the power flows are calculated in each. From these simulations, the results obtained in voltage profiles, namely active and reactive power losses, current levels, and the costs associated with the conductors used, are recorded. With the multi-criteria technique, the winning alternative is the design scenario containing the best joint solutions for the analysis variables. The proposed methodology is validated in an IEEE 34-bar test system. The Matpower tool, available through Matlab, generates power flows for each proposed design case. The results obtained in the analysis variables are generated and stored in a decision matrix of 210 alternatives. The proposed method represents a novel and powerful alternative for design proposals of distribution systems considering quality, efficiency, and cost criteria. Full article

This study was conducted in order to examine the impact of magnetite (Fe₃O₄), a conductive material capable of promoting direct interspecies electron transfer (DIET) among microorganisms, on the efficiency of anaerobic digestion in a plug flow reactor (PFR) using food wastewater (FW) as the substrate. The effects of recovering and replenishing magnetite discharged along with the digestate during continuous operation of the PFR were also evaluated. A PFR with a total volume of 17 L was utilized as the reactor for anaerobic digestion. The inoculum was obtained from Icheon Biogas Research Facility, which operated with a mixture of pig slurry and FW in a 7:3 (w/w) ratio. FW was used as the substrate (volatile solids (VS) content of 85,865 mg-VS/L). The PFR was set for operation at 39 °C, and after a stabilization period of approximately 82 days, the hydraulic retention time (HRT) was set at 40 days. The study was conducted in three stages: stage 1 (83~122 days), stage 2 (123~162 days), and stage 3 (163~202 days). For the maintenance of an organic loading rate of 2.12 kg-VS/m³/d, 0.3 L/d of substrate was added every 24 h, and analysis of an equal amount of discharged digestate was performed. The experimental treatments included a control without the addition of magnetite after the stabilization period, treatment (T1) with addition of magnetite (20 mM in digestate) and subsequent recovery and replenishment of magnetite on the discharge of digestate, and treatment (T2) with addition of magnetite (20 mM) without the replenishment of magnetite. Analytical parameters included the characteristics of the discharged digestate (pH, NH₄⁺-N, chemical oxygen demand (COD_Cr), total volatile fatty acids (TVFAs), and alkalinity), and methane production (M_p). During the period of operation of the PFR after the stabilization period, no significant differences in pH and NH₄⁺-N, based on the recovery and replenishment of magnetite, were observed, and a stably functioning PFR was observed. However, in stage 2, due to the increased degradation of organic matter caused by DIET, the COD_Cr of T1 and T2 decreased by 9.42% compared with the control. In stage 3, the magnetite content in the reactor in T2 decreased by a maximum of 9.42% compared to T1. In stage 3, the M_p for T2 was similar to that of the control, with a maximum discharge of magnetite of 3.06%, and the M_p decreased by 5.40% compared to T1. Regarding the ratio of methanogens in the community, the results of an analysis of the digestate from stage 3 showed an increase in the community of acetotrophic methanogens, specifically Methanosarcina. The findings of this study confirm that DIET was effectively promoted by maintaining the concentration of 20 mM magnetite in the PFR while using FW as a substrate. Full article