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DOE OSTI2021

Decentralized Failure-Tolerant Optimization of Electric Vehicle Charging

We present a decentralized failure-tolerant algorithm for optimizing electric vehicle (EV) charging, using charging stations as computing agents. The algorithm is based on the alternating direction method of multipliers (ADMM) and it has the following features: (i) It handles capacity, peak demand, and ancillary services coupling constraints. (ii) It does not require a central agent collecting information and performing coordination (e.g. an aggregator), instead all agents exchange information and computations are carried out in a fully decentralized fashion. (iii) It can withstand the failure of any number of computing agents, as long as the remaining computing agents are in a connected communications network. We construct this algorithm by reformulating the optimal EV charging problem in a decomposable form, amenable to ADMM, and then developing efficient decentralized solution methods for the subproblems dealing with coupling constraints. We conduct numerical experiments on industry-scale synthetic EV charging datasets, with up to 1,152 charging stations, using a high performance computing cluster. The experiments demonstrate that the proposed algorithm can solve the optimal EV charging problem fast enough to permit the integration of EV charging with real-time electricity markets, even in the presence of failures.

42 ENGINEERING↗

DOE OSTI2024

Recommended Actions to Improve Adapter Safety

With the rapid advancement and acceleration in the electric vehicle (EV) industry within the United States, major automakers and EV charging companies are increasingly adopting the North American Charging Standard (NACS) connector style, now officially known as J3400. This shift is expected to enhance charging infrastructure, providing a better customer experience by making it easier for all EV drivers to access a wider network of direct-current (DC) fast chargers (DCFCs). However, the adoption of the J3400 standard presents challenges for many EVs already on the roads and some currently coming off production lines that are equipped with the Combined Charging System (CCS) connector, which this report will refer to as the North American standard, CCS1. These vehicles will need adapters to use new or existing J3400 infrastructure. During this transition, several issues have emerged. Firstly, there is a need to standardize the new connector type to ensure it is interoperable, safe, and reliable. Second, existing CCS EV drivers need a way to access the J3400 network, which will require electric vehicle supply equipment (EVSE) or sites with both connector types, driver-provided adapters to physically convert from CCS to J3400, or EVSE with retained adapters designed for use with the EVSE. Third, adapter standards will need to be written to specify how they will be designed and what evaluations will be needed to ensure safe and reliable performance. To address these challenges, adapters that support different types of charging connectors will be essential. These adapters will play a crucial role in supporting the transition and ensuring continued service for legacy EVs with CCS inlets as the J3400 standard becomes the predominant one in the United States. Consequently, the National Charging Experience (ChargeX) Consortium has investigated and performed a teardown analysis on the different adapter versions on the market. The aim is to create a failure mode and effects analysis (FMEA) on what are expected to be the most common adapter types used in this transition. In order to support this work, we executed an FMEA exercise with the main goal of identifying gaps in the existing adapters' performance and conformance to the most common safety requirements of high-power and high-voltage devices. This effort focused on adapters provided by the driver, as these may present the highest safety and reliability risks. The recommendations made here apply to both retained and driver-provided adapters.

25 ENERGY STORAGE↗

DOE OSTI2026

Evaluations of Connectors, Inlets, and Adapters on Side-Load and Withstand Force

This report examines the mechanical forces that direct current fast charging (DCFC) electric vehicle supply equipment (EVSE) connectors and electric vehicle (EV) inlet ports experience during normal usage. As we witness the fast and growing variety of EVs, charge port locations, and bigger and more powerful EVSE configurations including the SAE J3400 North American Charging Standard (NACS), which has increased the use of adapters with J3400 and J1772 compatibility. These new conditions contribute to increased mechanical forces due to their size, weight and lever arm effect, which creates the need to study and compare these forces to the limits on UL2251 and IEC 62196-1 standards. This report focuses solely on high power DC charging EVSE connectors, EV inlets and adapters for the specific compatibility cases on J3400 with J1772. We first describe the details of the 100N and the 750N side-load evaluations as described in the standards, then present the data obtained by replicating these tests to finally go into more detail on the findings and our recommendations.

100N↗

DOE OSTI2023

Connecting Electric Vehicle Charging Infrastructure to Commercial Buildings

Electric vehicles (EVs) are growing in popularity and gaining meaningful market share with record sales year over year in the last decade. EV charging equipment, also known as EV chargers (EVC) or EV supply equipment (EVSE), must proportionally match the growing number of new EVs on the road for a comparable experience to gas-powered vehicles. The majority of EV charging currently happens at residential buildings. However, demand for EV charging at commercial buildings will significantly increase with wider mainstream EV adoption and as businesses return to more normal operation following COVID-19 pandemic disruptions. Charging equipment can include various sub-systems like power conditioning module, control software, safety devices, metering, communication, cooling, connectors, and its wiring. EV charging at commercial buildings could be used for public, workplace, and commercial fleet charging. This document aims to describe how EVC can be connected to commercial buildings, including considerations for facility managers, and the effects that charging will have on the buildings electrical distribution system. More specifically, this resource provides an overview of: understanding EV charging basics: how charging equipment connects to the building and to EVs; required infrastructure updates needed at the building site to connect EVC to existing distribution systems; network strategies for cost-effective operation; metering and utility considerations for billing and incentives; charging equipment ownership options; future trends in EVC connection to buildings.

ADVANCED PROPULSION SYSTEMS,ENERGY CONSERVATION, C↗

DOE OSTI2023

Estimating the electric vehicle charging demand of multi-unit dwelling residents in the United States

Abstract Early battery electric vehicle (EV) adopters can access home chargers for reliable charging. As the EV market grows, residents of multi-unit dwellings (MUDs) may face barriers in owning EVs and charging them without garage or parking availability. To investigate the mechanisms that can bridge existing disparities in home charging and station deployment, we characterized the travel behavior of MUD residents and estimated their EV residential charging demand. This study classifies the travel patterns of MUD residents by fusing trip diary data from the National Household Travel Survey and housing features from the American Housing Survey. A hierarchical agglomerative clustering method was used to cluster apartment complex residents’ travel profiles, considering attributes such as dwell time, daily vehicle miles traveled (VMT), income, and their residences’ US census division. We propose a charging decision model to determine the charging station placement demand in MUDs and the charging energy volume expected to be consumed, assuming that MUD drivers universally operate EVs in urban communities. Numerical experiments were conducted to gain insight into the charging demand of MUD residents in the US. We found that charging availability is indispensable for households that set out to meet 80% state of charge by the end of the day. When maintaining a 20% comfortable state of charge the entire day, the higher the VMT are, the greater the share of charging demand and the greater the energy use in MUD chargers. The upper-income group requires a greater share of MUD charging and greater daily kWh charged because of more VMT.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Levelized cost of charging of extreme fast charging with stationary LMO/LTO batteries

Extreme DC fast charging for electric vehicles (EVs) could be competitive with the internal combustion engine refueling experience and enable longer-distance travel, which could help with EV adoption and decarbonization, but these systems have high capital costs and extremely variable high-power demands. Behind-the-meter systems (BTMS) could support extreme-fast-charging (XFC) stations to increase nationwide adoption of EVs. Here, this study examines the optimal break-even levelized cost of charging (LCOC) across 96 BTMS scenarios to enable low-wait XFC stations providing 200 miles of charge in 10 min. This research simulates LCOC via synthetic XFC-capable EV loads, machine-learned battery life models from testing data, and nonlinear optimal controls, co-minimizing complex utility costs and battery replacements. An aggregate optimal BTMS design treating each EV load as equal likely gives an optimal LCOC per utility rate, the average of which is $\$$0.59/kWh. In addition, the sensitivity of optimal and off-optimal design factors, the long-life LMO/LTO chemistry, and optimized controls are analyzed. The battery control model, based on battery stressors to compare chemistries, optimizes LMO/LTO resting state of charge and cycle depth without compromising cost reduction, which enables greater flexibility in operation. The LCOC savings due to replacement reduction are small, up to $\$$0.035/kWh (6%), with an average of $\$$0.02/kWh (3.5%). Compared with gasoline stations, the aggregate XFC station design achieves comparable speed, experience of service, and cost at $\$$3.81/gal gasoline, showing that EVs can replace gasoline vehicles even for longer-distance travel.

25 ENERGY STORAGE↗

DOE OSTI2023

Customer Experience at Public Charging Stations and Its Effects on the Purchase and Use of Electric Vehicles

To support the ChargeX Consortium’s mission to measure and significantly improve the reliability and usability of public charging infrastructure in North America, researchers in the consortium from the University of Washington (UW) reviewed the published literature and data from consortium members to evaluate how the consumer experience at public fast charging stations influences electric vehicle (EV) adoption.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

SULI Oral Presentation

Furthering our understanding of the prevalence and severity of issues that customers face when charging their electric vehicles (EVs) is crucial in order to improve the charging experience across the United States. This project utilizes web-scraping, machine leaning (ML), and natural language processing (NLP) techniques to analyze and categorize user-generated reviews. Selenium was used to build a data collection tool that can scrape vast amounts of user review data from the PlugShare website. Sentiment analysis was employed on this dataset in order to filter out negative reviews for further analysis. NLP techniques such as tokenization and word embedding were then used to convert user-written comments into a numerical format that a ML model can interpret. Multiple ML approaches are currently being explored in order to identify and categorize the charging issues being talked about in each review. Ultimately, the results from the ML model will be visualized and explained in a report on customer pain points to be delivered to the ChargeX Consortium, therefore revealing specific areas for improvement in the customer charging experience.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

SULI Oral Presentation

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

High-Efficiency, Medium-Voltage-Input, Solid-State-Transformer-Based 400-kW/1000V/400A Extreme Fast Charger for Electric Vehicles

Range anxiety and long battery charging time continue to be critical challenges to mass adaptation of EVs. A major identified gap to wider adoption of BEVs is the ability and availability to refuel quickly or to fast charge. Studies have shown that in areas where drivers have access to 50-kW or 120-kW fast charge stations, annual electric vehicle (EV) miles traveled (i.e., eVMT) increased by over 25%, even in cases where fast charging was used for 1% to 5% of total charging events. Charge stations of higher power not only alleviate the “range anxiety” and reduce the driver’s waiting time, but also requires less investment. Michigan Energy Office completed a study in early 2019 titled “Electric Vehicle Charger Placement Optimization in Michigan: Phase I – Highways”. This study finds a system with 150kW chargers, though more expensive individually, actually has lower total system cost when compared to a 50kW charging system when serving the same battery size EV. To be truly competitive to the ICEV refueling experience, even higher power stations are necessary. However, high power charge stations would create large power draws from the grid. If this occurs during peak demand periods, grid capacity could be overloaded. This problem needs to be addressed to reduce the impact on the electric utility infrastructure. The main goal of this project is to develop a 400-kW/400-A XFC system targeting total efficiency of 96.5 percent from the MVAC grid to a vehicle. The novel SST power cell topology, combined with a new silicon carbide (SiC) MOSFET device, enables a 3.5 percent improvement in system efficiency, a 50-percent smaller equipment footprint, and four times less weight than today’s DCFC systems. The SST technology would directly utilize MVAC at 4.8-kV or 13.2-kV. This would eliminate the line frequency transformer (LFT), which steps down medium-voltage AC to 3-Phase 480-V line-to-line voltage in current DCFC systems.

42 ENGINEERING↗

DOE OSTI2022

Feasibility Study of Real-Time Carbon Emission Responsive Electric Vehicle Charging Control in Buildings: Preprint

With the progressing electrification of the transportation sector, the source of carbon emissions is gradually shifting from fossil fuel to grid electricity because of electric vehicles (EVs). The carbon intensity of the grid can fluctuate significantly within hours due to the time-varying power generation mix. Therefore, shifting EV charging loads to cleaner hours in response to the carbon intensity signals can reduce carbon emissions. Existing EV charging control methods typically consider the electricity price or the available generation by distributed energy resources (e.g., photovoltaics) to inform decision-making. Such methods tend to reduce energy costs but may neglect the environmental impact of EV charging activities. We propose and compare four carbon emission responsive EV charging controllers with various control rules. The proposed controllers are evaluated based on simulation experiments using metrics such as carbon emission reduction potential, state of charge (SOC) at departure, and peak demand. We found that the need of EV owners to have full batteries at departure could lead to an emission increase when the curtailed EV charge was compensated before departure. Further, up to 12.7% of carbon emission reduction can be achieved if the EV owners reduce the target SOC at departure by less than 15%.

carbon emission↗

DOE OSTI2026

Proposal for Direct Detection of Ultralight Dark Matter via Charged Lepton Flavor Violation

We propose a dark matter direct-detection strategy using charged particle decays at accelerator-based experiments. If ultralight ( m ϕ ≪ eV ) dark matter has a misalignment abundance, its local field oscillates in time at a frequency set by its mass. If it also couples to flavor-changing neutral currents, rare exotic decays such as μ → e ϕ ′ and τ → e ( μ ) ϕ ′ inherit this modulation. Focusing on such charged lepton flavor-violating decays, we show that sufficient event samples can enable detection of ultralight dark matter candidates at Mu3e, Belle-II, and FCC-ee.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Multi-layered Energy Management Framework for Extreme Fast Charging Stations Considering Demand Charges, Battery Degradation, and Forecast Uncertainties

To achieve a cost-effective and expeditious charging experience for extreme fast charging station (XFCS) owners and electric vehicle (EV) users, the optimal operation of XFCS is crucial. It is however challenging to simultaneously manage the profit from energy arbitrage, the cost of demand charges, and the degradation of a battery energy storage system (BESS) under uncertainties. This paper, therefore, proposes a multi-layered multi-time scale energy flow management framework for an XFCS by considering long- and short-term forecast uncertainties, monthly demand charges reduction, and BESS life degradation. In the proposed approach, an upper scheduling layer (USL) ensures the overall operation economy and yields optimal scheduling of the energy resources on a rolling horizon basis, thereby considering the long-term forecast errors. A lower dispatch layer (LDL) takes the short-term forecast errors into account during the real-time operation of the XFCS. Per the latest research, monthly demand charges can be as high as 90% of the total monthly bills for EV fast charging stations; to this end, this paper takes the first attempt at the reduction of demand charges cost by considering the trade-off between the energy cost and monthly demand charges. Contrasting literature, this work allocates an energy reserve in the BESS stored energy to deal with the impact of short-term forecast errors on the optimized real-time operation of the XFCS. Moreover, degradation modeling considers the trade-off between short-term benefits and long-term BESS life degradation. As a result, case studies and a comparative analysis prove the efficacy of the proposed framework.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Safe Deep Reinforcement Learning for Active Distribution System Model Predictive Control with EVs and DERs

The temporal and spatial mismatch between PV generation and electric vehicle (EV) charging and discharging may cause voltage violations in active distribution networks. Despite the widespread use of deep reinforcement learning (DRL) in power system optimization and control, it lacks guarantees on constraint satisfaction during both training and deployment. This paper proposes a Lagrangian-based safe DRL approach for model predictive control (MPC) of active distribution systems with large-scale integration of PVs, EVs, and energy storage systems (ESSs). A Transformer-LSTM time-series model is proposed to forecast EV charging demand, which is then formulated as a constraint to ensure charging requirements are met. Using this prediction, a Lagrangian-based safe soft actor-critic (SAC) framework is developed for real-time control in a three-phase unbalanced distribution system, enforcing voltage safety constraints while optimizing the cumulative net reward. By integrating the forecasting model with multi-period constraints, the proposed framework jointly coordinates PV systems, EV charging and discharging, and ESS scheduling within the MPC horizon. Numerical experiments on a modified IEEE 123-bus system with real-world data show that, under a high PV penetration scenario, the proposed method increases the net reward by 30.74% and reduces average voltage violations from 0.0011 p.u. to 0.0002 p.u. compared with standard SAC. Compared with the optimal power flow (OPF) approach, it achieves similar voltage security while yielding lower line losses. It also maintains real-time control capability, reducing operation latency to 53.21 ms per 15-minute control interval. The proposed method remains effective under varying PV/EV penetrations and load conditions.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

USAID Colombia Young Leaders Workforce Training Program Action Plans: Planning for Electric Vehicle Charging Infrastructure in Bogotá

As part of the U.S. Agency for International Development (USAID)-National Renewable Energy Laboratory (NREL) Young Leaders Workforce Training Program in Colombia, the Grupo Energía Bogotá (GEB) participants leveraged their training and professional experience to develop an action plan for modeling and evaluating Bogotá's projected electric vehicle (EV) charging needs to meet future demand. This case study summarizes the collaboration between USAID-NREL, GEB, and the Bogotá Department of Transportation Mobility Secretariat (SDM) to estimate EV charging station needs to meet projected future EV sales in the city of Bogotá and determine high-priority locations within the greater Bogotá metropolitan area for planning and applying EVSE investment and installation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Precision measurement of Compton scattering in silicon with a skipper CCD for dark matter detection

Experiments aiming to directly detect dark matter through particle recoils can achieve energy thresholds of $\mathcal{O}(1\,\mathrm{eV})$. In this regime, ionization signals from small-angle Compton scatters of environmental $\gamma$-rays constitute a significant background. Monte Carlo simulations used to build background models have not been experimentally validated at these low energies. We report a precision measurement of Compton scattering on silicon atomic shell electrons down to 23$\,$eV. A skipper charge-coupled device (CCD) with single-electron resolution, developed for the DAMIC-M experiment, was exposed to a $^{241}$Am $\gamma$-ray source over several months. Features associated with the silicon K, L$_{1}$, and L$_{2,3}$-shells are clearly identified, and scattering on valence electrons is detected for the first time below 100$\,$eV. We find that the relativistic impulse approximation for Compton scattering, which is implemented in Monte Carlo simulations commonly used by direct detection experiments, does not reproduce the measured spectrum below 0.5$\,$keV. The data are in better agreement with $ab$$initio$ calculations originally developed for X-ray absorption spectroscopy.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Rooftop Photovoltaics and Electric Vehicle Co-Adoption: Attitudes, Norms, Diffusion, and Economics

The overall objectives of the project were to (1) Identify personal and social norms, peer effects, demographics and contextual factors (such as household energy expenditures, experience with outages, charging infrastructure availability) that may facilitate or hinder Solar-EV co-adoption; (2) outline strategies for the design of programs and practices that will enable reasoned RPV and EV adoption and their co-adoption; and (3) assemble a dataset comprised of survey responses of RPV-EV co-adopters, RPV-only adopters, EV-only adopters, and non-adopters. These objectives were only partially fulfilled given the decision to terminate the project. The research team was able to complete the semi-structured interviews, the core BY1 task and summarize the results below. As well, once the team learned of the research project’s fate, it sought and obtained the DOE SETO Technical Manager’s approval to repurpose funds for BY2 tasks to the extent feasible. Rather than invest further resources in expanding the pool of potential survey respondents and having no budget to survey, the research team repurposed funds subject and undertook a more limited (geographically) survey, but also expanded to it to include contingent valuation questions. The analysis of the survey data will necessarily be delayed given the lack of budget support, although some information on the respondent sample is in the results. Given a lack of attention to co-adoption previously, the insights generated in this project should assist decision-makers and industry actors in the development of programs and practices that enable reasoned RPV adoption and EV adoption and their co-adoption.

14 SOLAR ENERGY↗

DOE OSTI2024

MaDEVIoT: Cyberattacks on EV Charging Can Disrupt Power Grid Operation

Extensive roll-out of electric vehicles (EVs) requires large-scale deployment of high-power EV Charging Stations (EVCSs). EVCSs are connected to the internet using Internetof- Things (IoT) such as smartphones, to improve the charging experience of users and increase their profitability. This paper studies the feasibility of demand-side cyberattacks launched on power grids via such internet-connected highpower EVCSs. The attack mechanism distorts power grid frequency and voltage, and has the potential to trigger systemwide outages. The case study, based on the power grid and EV deployment plans in Manhattan, New York, illustrates potential impacts of such attacks. The results show that such attacks will become feasible in Manhattan, New York in 2030, as EV adoption increases. Furthermore, the attacks in 2030 are feasible even compromising a single company’s EVCS server in Manhattan, New York. The attacks can cause line overloads and trip over-frequency protection relays, causing system-side blackout in the power grid in Manhattan, New York. The paper informs planning authorities and power grid operators involved with the roll-out of EV charging infrastructure about potential cyberthreats to power grids via manipulating internet-connected high-power EVCSs.

Acharya, Samrat S.↗