Case Studies in Thermal Engineering最新文献

{"title":"Pareto-based multi-objective design of battery cold plates with leaf-inspired bifurcations using arithmetic optimization algorithm and WASPAS technique","authors":"Hatem Gasmi ,&nbsp;Borhen Louhichi ,&nbsp;Ali Basem ,&nbsp;As'ad Alizadeh ,&nbsp;Mohamed Shaban ,&nbsp;Mujtaba A. Flayyih ,&nbsp;Wajdi Rajhi ,&nbsp;Khalil Hajlaoui","doi":"10.1016/j.csite.2026.107869","DOIUrl":"10.1016/j.csite.2026.107869","url":null,"abstract":"<div><div>Efficient thermal management is essential for ensuring the safety, reliability, and longevity of Li-ion batteries, yet liquid-cooled plate (LCP) designs face persistent challenges in balancing cooling efficiency with hydraulic performance. This study presents an AI-based integrated workflow for the design and optimization of LCPs featuring leaf-inspired bifurcation geometries. The framework consists of four sequential stages: data analysis, predictive modeling using GMDH-type ANN, Pareto-based optimization via multi-objective arithmetic optimization algorithm (MOAOA) and multi-objective particle swarm optimization (MOPSO), and final design ranking with the WASPAS decision-making method. The GMDH models demonstrated high predictive accuracy, achieving R² &gt; 0.99 for thermal resistance and pressure drop. Both MOAOA and MOPSO produced nearly identical Pareto fronts, confirming robustness in capturing trade-offs between thermal and hydraulic performance. Optimized inputs revealed balanced designs at mass flow rates of 0.8–1.5 g/s, channel widths of ∼3.7–3.9 mm, and heights of 2.4–2.5 mm, achieving thermal resistance of 0.25–0.35 K/W with pressure drops of 10–25 Pa, ensuring efficient cooling without excessive hydraulic penalties. Decision analysis revealed context-specific optimal designs, ranging from ultra-low thermal resistance (0.1793 K/W) at the cost of high pressure drop (106.81 Pa) to energy-efficient solutions with minimal pumping penalties (ΔP = 2.14 Pa).</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107869"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147330305","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Structural optimization of multi-heat-source cold plates using neural network and genetic algorithm","authors":"Yifei Zhang,&nbsp;Yubin Zhuang,&nbsp;Pan Cui,&nbsp;Wei Liu,&nbsp;Zhichun Liu","doi":"10.1016/j.csite.2026.107851","DOIUrl":"10.1016/j.csite.2026.107851","url":null,"abstract":"<div><div>This study proposes an integrated framework coupling neural networks with the Non-Dominated Sorting Genetic Algorithm II (NSGA-II) for the independent multi-zone optimization of fin structures in both straight-fin and hybrid-fin cold plates, addressing the thermal management challenge of multi-heat-source configurations. The framework systematically investigates how zonal fin parameters regulate thermo-hydraulic performance, with optimization conducted under two distinct objectives. Results vs. the initial design show: minimum-pressure-drop designs cut flow resistance by 47.4% (straight-fin) and 52.9% (hybrid-fin), while balanced designs reduced it by 28% and 38.4% respectively, with improved temperature uniformity. Direct comparison with traditional global optimization (uniform fin parameters) shows the traditional method only cut flow resistance by 19.3%, versus 34.9–41.7% for ours, plus targeted thermal management unavailable to uniform designs. Hybrid-fin designs exhibit superior overall performance, particularly in zone <em>R2</em> (high-power devices), enhancing heat dissipation without hydraulic compromise. Mechanistic analysis reveals outlet zone (<em>R1</em>) parameters dominate pressure drop due to local resistance losses, inlet zone (<em>R3</em>) is sensitive to downstream undeveloped flow, and intermediate zone (<em>R2</em>) behaves thermally independently with fully developed flow. Fin count modulates convective intensity via area-velocity effects, while fin thickness regulates thermal conduction and uniformity. This zonal control methodology cuts pumping power while ensuring thermal safety for uneven heat sources. The framework provides scalable optimization for multi-heat-source cold plates, enabling flexible strategy formulation per application-specific thermo-hydraulic priorities.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107851"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147330095","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Multi-objective optimization of burner configurations in sintering ignition furnace: A CFD-based orthogonal test with matrix analysis","authors":"Zhengzong Huang ,&nbsp;Jingfan Chen ,&nbsp;Xia Wu,&nbsp;Zongya Wang,&nbsp;Dongling Wu,&nbsp;Liu Liu,&nbsp;Hongjie Yan","doi":"10.1016/j.csite.2026.107908","DOIUrl":"10.1016/j.csite.2026.107908","url":null,"abstract":"<div><div>To achieve a comprehensive parameter optimization scheme for the sintering ignition furnace that facilitates energy conservation and productivity improvement, multi-objective optimization research on the burner configurations has been implemented by using computational fluid dynamics. An L₉(3³) orthogonal test was designed to focus on three key burner configuration parameters: ignition burner inclination angle, main burner airflow area, and main burner arrangement. Based on the range and matrix analyses, the orthogonal test results are meticulously analyzed, culminating in the identification of the optimal scheme. The optimization benefits are demonstrated through comparative analysis. Results indicate that the main burner arrangement affects the ignition quality most significantly, followed by the ignition burner inclination angle, with the main burner airflow area having the least impact. The optimal configuration includes setting the ignition burner inclination angle at 15°, the main burner airflow area at 1540 mm², and a “7 + 7″ uniform arrangement for the main burner. The flow field stability enhances markedly; the flame jet rigidity increases substantially; the burner jets mutual interference diminishes notably; the temperature field in the ignition section improves significantly. Compared to the baseline case, the average temperature in the ignition section increases by 40 K, while the temperature uniformity coefficient decreases by 4.99%.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107908"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147360582","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Thermodynamic and thermoeconomic analysis of an intercooled regenerative reheat gas turbine cogeneration system: A case study for Côte d’Ivoire, West Africa","authors":"Kousso Karell Kevine Andoh ,&nbsp;Ali Husnu Bademlioglu","doi":"10.1016/j.csite.2026.107892","DOIUrl":"10.1016/j.csite.2026.107892","url":null,"abstract":"<div><div>In this study, the gas turbine cogeneration system planned to be established in Côte d’Ivoire, West Africa was modeled and the thermodynamic and thermoeconomic performance of the system was investigated. Energy, exergy, and economic analyses were conducted for the system, which consists of an intercooled regenerative reheat (IRR) gas turbine cycle and an absorption refrigeration cycle (ARC), for various operating parameters. Within the scope of the study, the effects of pressure ratio (8–16), compressor isentropic efficiency (80–88%), turbine isentropic efficiency (75–85%), generator temperature (90–100 °C), and evaporator temperature (0–5 °C) on system performance were evaluated, and accordingly, the energy utilization factor (EUF), levelized cost of electricity (LCOE), and levelized cost of cooling (LCOC) were determined. Additionally, the analyses were conducted under different ambient temperature conditions to evaluate the system's performance under typical temperature scenarios observed in Côte d’Ivoire. Depending on the investigated parameter ranges, the energy efficiency of the IRR gas turbine varied between 35.17 and 42.72%, while the exergy efficiency ranged from 35.85 to 44.05%. In addition, the EUF of the IRR gas turbine cogeneration system varied between 60.43 and 63.30%, whereas the LCOE and LCOC ranged from 0.02527 to 0.04682 USD/kWh and 0.04839–0.07054 USD/kWh, respectively. Overall, the results highlight that the investigated operating parameters significantly affect the thermodynamic and thermoeconomic performance of the proposed IRR gas turbine cogeneration system.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107892"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147360583","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Synergistic effects of palm oil and cordierite partial-flow particulate filter on thermal efficiency and emission characteristics of a 2.5L diesel vehicle","authors":"Huy Quang Dang ,&nbsp;Mek Srilomsak ,&nbsp;Preechar Karin ,&nbsp;Sompong Srimanosaowapak ,&nbsp;Vitoon Uthaisangsuk ,&nbsp;Chinda Charoenphonphanich","doi":"10.1016/j.csite.2026.107911","DOIUrl":"10.1016/j.csite.2026.107911","url":null,"abstract":"<div><div>This study experimentally evaluates the synergistic effects of palm oil biodiesel fuels and a cordierite-based partial-flow diesel particulate filter (P-DPF) on the thermal efficiency and emission characteristics of a 2.5L light-duty diesel vehicle, using commercial fuels (B7 and B10) and neat biodiesel (B100). Steady-state chassis dynamometer tests showed that P-DPF installation increased exhaust backpressure by up to 7.2 kPa while causing only minor changes in fuel consumption and brake thermal efficiency. Under the New European Driving Cycle, B100 inherently reduced particulate number (PN) and mass (PM) by more than 43% and 32%, respectively, compared to commercial fuels. The integration of the P-DPF further reduced PN by 36–40% and PM by 57–60%. In addition, catalytic oxidation decreased CO and THC emissions by up to 20–25%, while NOx emissions were reduced by up to 20%, likely due to the combined effects of biodiesel properties and mild internal EGR induced by increased backpressure. Despite these improvements, the combined application remained insufficient to meet the Euro 5 limit but supported partial compliance with Euro 4 standards. These results demonstrate a practical and cost-effective retrofit strategy for reducing emissions from aging diesel vehicles.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107911"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147360820","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Numerical simulation of fractional electro-osmotic Walter-B flow in a magnetized porous medium with Soret–Dufour and chemical reaction effects","authors":"Mumtaz Khan ,&nbsp;M.S. Anwar","doi":"10.1016/j.csite.2026.107912","DOIUrl":"10.1016/j.csite.2026.107912","url":null,"abstract":"<div><div>The thermal management of microfluidic devices and renewable energy systems relies heavily on the efficient transport of non-Newtonian fluids. Specifically, these electro-kinetic and transport mechanisms are directly applied in the real-world design of electro-kinetic micropumps and biomedical lab-on-a-chip devices. Fractional calculus extends classical differentiation to non-integer orders, enabling realistic modeling of systems with memory and spatial nonlocality. This study examines the unsteady electro-osmotic flow of a Walter-B viscoelastic fluid past a semi-infinite vertical plate embedded in a Darcy porous medium under a transverse magnetic field. The model incorporates thermal radiation, internal heat generation, Soret-Dufour cross-diffusion, and a first-order chemical reaction, while Caputo fractional derivatives are used to represent memory-dependent heat and mass diffusion mechanism. The governing equations are non-dimensionalized and solved numerically using a fully implicit finite-difference scheme based on the second-order fractional backward-difference formula (FBDF2), ensuring stability and accuracy. To the best of the authors’ knowledge, this is the first study that combines fractional electro-osmotic Walter-B flow with simultaneous Soret–Dufour effects and chemical reaction within an FBDF2-based fully implicit finite-difference framework. The results reveal that smaller fractional orders intensify memory effects and delay thermal and solutal relaxation, reflecting the inherent nonlocality of fractional transport. Quantitatively, the Soret number enhances the heat transfer rate by approximately 5.38% while reducing the mass transfer rate by about 11.02%. The radiation parameter markedly improves thermal transport, producing nearly 33.36% enhancement in the Nusselt number. In contrast, the thermal Grashof number slightly reduces the skin-friction coefficient by 3.20%, whereas the electro-osmotic parameter decreases it by 7.95%. Moreover, the Dufour number yields a modest 2.10% increase in the Sherwood number.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107912"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147387309","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Digital transformation of conventional shell-tube heat exchanger using digital twinning and machine learning","authors":"Zhi Zhu ,&nbsp;Hao He ,&nbsp;Tosin Famakinwa ,&nbsp;Y.X. Zhang ,&nbsp;Helen Wu ,&nbsp;David Fox ,&nbsp;Richard (Chunhui) Yang","doi":"10.1016/j.csite.2026.107932","DOIUrl":"10.1016/j.csite.2026.107932","url":null,"abstract":"<div><div>Numerical simulation-based digital twins are emerging as a transformative technology capable of significantly enhancing operational efficiency and minimising costly maintenance and human intervention for smart products and services. However, the inherent limitations of physical monitoring and the uncertainties associated with product or service performance can be effectively addressed through the strategic application of parameterised numerical models combined with advanced machine learning (ML) algorithms. To address the research gap, this research investigates how a novel and systematic digital-twin-based design and analysis approach can facilitate the transformation of a conventional Shell-and-Tube Heat Exchanger (STHE) into a smart machine within the evolving framework of Industry 4.0. The methodology involves devising a data-driven digital twin (DT) for the STHE, utilising coupled Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) simulations to numerically investigate key performance parameters. This process enables the integration of virtual sensors, the fusion of physical measurements, and the deployment of advanced machine learning algorithms to precisely identify critical points for sensor and actuator placement in an Internet of Things (IoT)-based machine condition monitoring (MCM) system. The developed STHE digital twin successfully demonstrates its capability to extract data of key performance parameters, which enables seamless integration with sensors and actuators. This digital twinning further empowers a digital design and prototyping process for visualiszed, real-time IoT based machine condition monitoring. Advanced ML algorithms are employed to identify the locations of the critical points in the STHE, where sensors are installed for IoT-based MCM. The developed STHE DT demonstrates its capability of extracting crucial data based on fundamental principles of mass, energy, and momentum, facilitating seamless integration with sensors. The underpinning concept, comprehensive methodological framework, and practical implementation process of the STHE digital twin presented herein provide a robust foundation. This work represents a significant scientific contribution towards enabling the transformation of conventional mechanical systems into intelligent, data-driven smart products, aligning with the objectives of Industry 4.0.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107932"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147387371","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study on the temperature uniformity of lithium batteries based on gradient porous metal foam saturated liquid cooling plate","authors":"Wenhao Li ,&nbsp;Yinxiang Wu ,&nbsp;Min Huang ,&nbsp;Zhenyong Liu","doi":"10.1016/j.csite.2026.107923","DOIUrl":"10.1016/j.csite.2026.107923","url":null,"abstract":"<div><div>To improve the thermal management and temperature uniformity of lithium-ion batteries, this study proposes and evaluates a novel liquid cooling plate structure featuring gradient porous metal foam (GPFM). A fully integrated three-dimensional electrochemical-thermal coupled model was developed to accurately capture the battery's internal thermal behavior and assess the cooling plate's performance. The numerical simulations for this model were conducted using COMSOL Multiphysics. The study systematically investigated the influence of key input parameters—specifically, four distinct porosity gradient variations (defined by the gradient index n) and discharge rates (e.g., 2C, 5C, 7C)—on the primary output parameters: the battery's peak temperature and maximum temperature difference (<span><math><mrow><mo>Δ</mo><msub><mi>T</mi><mi>max</mi></msub></mrow></math></span>). The results indicate that the designed GPFM cooling plate effectively lowers the peak temperature while markedly improving thermal uniformity. The enhancement was most evident when the gradient variation index n = 2. The impact of the gradient design varied with the discharge rate. The maximum temperature reduction peaked at 13.5% under a 7C discharge rate. Conversely, the temperature difference achieved its highest percentage reduction of 58.1% at a 2C discharge rate. This study demonstrates that optimizing the porosity gradient design is an effective approach to enhancing temperature uniformity in lithium-ion batteries, particularly offering significant benefits under high-discharge-rate conditions.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107923"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147387427","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Modeling and thermal characteristic analysis of feed system considering multi-physical field coupling","authors":"Yabin Jing ,&nbsp;Xialun Yun ,&nbsp;Gedong Jiang ,&nbsp;Hanbo Yang ,&nbsp;Hu Shi ,&nbsp;Haitao Wang ,&nbsp;Xuesong Mei","doi":"10.1016/j.csite.2026.107925","DOIUrl":"10.1016/j.csite.2026.107925","url":null,"abstract":"<div><div>The feed system (FS), a critical component in machine tools, significantly impacts machining accuracy through its thermal characteristics. Accurate modeling of its contact mechanism and coupled physical fields is essential for determining precise boundary conditions (BCs), which are fundamental to thermal characteristic modeling. To address this, this study proposes a fluid-solid-thermal coupling strategy to calculate the BCs integrating film-structure-temperature, convection-structure-temperature, and thermo-mechanical coupling. This strategy is built on a contact mechanism model (RCCD-CF-GM-ARCT) incorporating raceway curvature center displacement, centrifugal force, gyroscopic moment effects, and adaptive raceway control theory. Subsequently, the thermal characteristic model (TC-MPFC-HM) is developed using the finite element method, based on the multi-physical field coupling strategy and the moving heat of the FS. Additionally, a closed-loop iteration algorithm is proposed to dynamically update BCs, ensuring accuracy and responsiveness. The results show significant improvements over traditional models, reducing RMSE by 77.54%, 82.81%, and 85.17%, and MAE by 78.4%, 82.06%, and 86.41% under various working conditions. These results validate that the model has enhanced precision and robustness, offering a comprehensive approach for thermal error modeling of FS.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107925"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147387429","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A comprehensive performance evaluation of a fuel-cell hybrid electric heavy-duty truck through energy flow experiment under user-defined driving test cycles","authors":"Renhua Feng ,&nbsp;Zhanye Hua ,&nbsp;Zhichao Zhao ,&nbsp;Faguang Li ,&nbsp;Xing Shu ,&nbsp;Licheng Luo ,&nbsp;Huikai Zhai","doi":"10.1016/j.csite.2026.107819","DOIUrl":"10.1016/j.csite.2026.107819","url":null,"abstract":"<div><div>This study experimentally investigates the energy flow characteristics of a fuel cell (FC) hybrid electric heavy-duty truck under user-defined driving cycles. The analysis comprehensively examines three critical aspects including energy consumption distribution patterns, efficiency metrics of key powertrain components, and thermal management system performance. The results show that the FC stack achieves 47.98% conversion efficiency but suffers 49.6% thermal losses through coolant systems with power fluctuations, resulting in only 38.99% of initial energy reaching the wheels after accounting for losses in power electronics, transmission and auxiliary systems. The power battery effectively balances loads but achieves only 26.1% energy recovery during deceleration and motor efficiency drops below 85% during medium-speed and low-torque operation in intermediate gears, indicating optimization potential for both energy recovery and shift strategies. Thermal management challenges emerge throughout the system with FC coolant temperature variations correlating with current changes while maintaining 10 °C differentials during load fluctuations. Under the current cooling configuration, the maximum temperature of the battery cell rose to 35 °C. Meanwhile, the motor temperature increased from 27 °C to 50 °C and then stabilized at 45-50 °C. Although the system achieved basic thermal management, there are limitations in handling the heat load at the battery end, indicating the need to further improve the cooling design by increasing cooling capacity or optimizing algorithms. Additionally, the 2-4 °C cabin temperature variations and compressor instability highlight heating, ventilation and air conditioning system needs for outlet redesign or control strategies enhancements. This study constructed a brand-new energy flow analysis framework for FCHE, which not only quantifies energy consumption distribution and powertrain component efficiency, but also conducts in-depth analysis of the thermal management system from multiple dimensions such as temperature response, heat loss mechanism, and subsystem coordination. This research also provides a reference for the subsequent improvement of the performance and engineering application of FC hybrid heavy-duty trucks.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107819"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146152788","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}