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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2022

A 1kV, 480V Power Electronics Hub for DER Integration in Commercial Buildings

Power electronic (PE) systems are increasingly being integrated into distribution and sub-distribution networks in support of distributed energy resource integration (DERs), electric vehicle (EV) charging (particularly in the case of fast charging infrastructure), and improvement in power quality for high performance computing and/or servers farms. This provides an opportunity to research and develop integrated PE systems that can function as single systems thereby bringing additional functionality and benefits to the overall system. The goal of this paper is to demonstrate foundational technologies and capabilities for a multiport power electronics energy hub that can intelligently coordinate and control integrated sources and loads. The focus for this digest is on a commercial building use case which is demonstrated in hardware.

Starke, Michael↗

DOE OSTI2026

EVSE Characterization

NextGen Profiles' EVSE characterization efforts explored performance variability in production EVSE through the use of EV emulation equipment and assessed how different operational conditions influence charging behavior. Data were collected at a frequency of 10 Hz from both the EV emulator and EVSE during each charge session and stored in a time-series database for further analysis. As part of the NextGen Profiles project, characterization of high-power EVSE was performed on both conductive and wireless charging infrastructure; however, only conductive charging data are currently included in this repository. This EVSE characterization was performed over a range of DC output currents and voltages, covering both nominal and off-nominal test conditions. This EVSE characterization dataset includes high-power charging data from two types of 350-kW-capable EVSE using liquid-cooled Combined Charging System-1 (CCS1, North American version) cables and connectors. To protect confidentiality, all EVSE metadata are anonymized, and the publicly released datasets are metered at 10-Hz frequency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Power-to-Gas Systems for Active Load Management at EV Charging Sites with High DER Penetration

Intermittent renewable systems and increasing electric vehicle (EV) penetrations increase load intermittency—and will require expensive distribution system infrastructure upgrades. Power-to-gas (P2G) systems are highly controllable loads that can be modulated to regulate the net load behind the meter. In this work, we present an active load management approach using P2G systems to regulate the net load for an EV charging station with high penetrations of renewable generation. The system also validates the feasibility of the proposed approach using a 750-kW electrolyzer operated with the distribution system in a real-time power-hardware-in-the-loop test. Finally, we evaluate the impact of the size of the P2G system on its ability to regulate the net load.

ADVANCED PROPULSION SYSTEMS,POWER TRANSMISSION AND↗

DOE OSTI2024

High-Power Oak Ridge Converter (ORC) for Extreme Fast Charging Applications

This project report presents a novel power converter system called Oak Ridge Converter (ORC), a patented technology developed by the Oak Ridge National Laboratory (ORNL) for XFC wireless EV charging systems. ORC integrates the grid interface converter (also known as the active front-end rectifier with power factor correction) with the high-frequency inverter stage, promoting size and cost-effective charging technology with reduced infrastructure costs. The integration of the front-end rectifier with the high-frequency inverter truly eliminates one power conversion stage and achieves more than 33% size, weight, volume, and cost reduction on the wireless charging systems. Furthermore, ORC eliminates the primary side direct current (DC) bus bulk capacitors that are usually aluminum electrolytic capacitors and replaces them with very small, cost-effective, highly reliable, and high-temperature operation-capable alternate current (AC) film capacitors. ORC is also applicable to both single-phase and poly-phase couplers. When used with polyphase couplers, ORC further improves the power density of the overall system with higher power density power electronics. Moreover, ORC is inherently bidirectional and allows the system to provide power back to the grid for grid ancillary or grid support services. The ORC, based on a patented ORNL technology, is an excellent approach to resolving the high-power charging problems as described above, which directly converts the 60 hertz (Hz) line frequency into high frequency (i.e., 85 kilohertz (kHz)) to use with a high-frequency isolation transformer or wireless charging coils while eliminating the primary side number of power conversion stages from two to one. The result of the project is a prototype and reference design for a high-power wireless charging system—including power electronics, magnetics, and thermal—serving as a baseline for product development. The proposed system results are demonstrated for 270 kW of output power, with the system's overall efficiency of 92% from the AC grid, achieving less than 3% current total harmonic distortion (THD) and around 0.99 power factor (PF).

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Projecting Recent Advancements in Battery Technology to Next–Generation Electric Vehicles

Electric vehicles (EVs) have seen rapid growth in adoption over the last several years. Advancements to increase battery life and performance, policy shifts, and high charging rate are expected to further accelerate the development of next generation of EVs. Battery improvements continue to emerge, enabling increased driving range, total distance driven over the life of vehicles, and ability to charge at high rates. Herein, an analysis framework to provide insights into inclusive design metrics, such as specific energy of batteries, energy consumption of vehicles, and charging power infrastructure development, is developed. Various cell-level fast charge protocols to realistic battery designs to understand the infrastructure needs associated with achieving range replacement of 32.25 km min -1 (20 mi min -1 ) are also scaled. Additionally, by calculating scaled power and peak to average power ratio, it is found that there needs to be more distinct alignment between the research efforts focused at the cell level and what is being developed for EV charging infrastructure needs. Finally, impact of high direct current voltage architecture in next-generation EVs is discussed. The findings in this work provide an insight into recent advancements in battery technology to next-generation EVs.

20 mi/min↗

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.↗

DOE OSTI2025

EV Charging Infrastructure Energization An Overview of Approaches for Simplifying and Accelerating Timelines to Processing EV Charging Load Service Requests

The United States has seen significant growth in electric vehicle (EV) adoption, leading to increased demand for EV charging infrastructure. Over the past decade, EV charging infrastructure site developers, site hosts, and electric distribution utilities have navigated the process to integrate chargers onto the electric grid. Site developers and site hosts have raised the alarm that the integration process for high-powered EV charging projects does not meet the needs of the EV market for timeliness or cost. High-powered charging stations typically require a load service request or an agreement with the local utility to connect to the grid. The process of energizing a new high-powered charging site can be complex and time-consuming, often taking up to 2 years. This timeline is the result of current utility energization processes having been designed for construction projects that take longer to build (i.e., buildings). The specific challenges stem from various factors, including compartmentalization in application processes, the integration of EV charging process approvals with other distributed energy resources (DERs), and the need to ensure grid reliability. The energization process needs to evolve to meet the growing demand for high-powered EV charging. This white paper compiles information gathered through various conversations with key stakeholders, including utilities, utility regulators, EV charging operators, site developers, and authorities having jurisdiction (AHJ) as well as through an extensive literature review. This document identifies the challenges and provides potential solutions to streamline the process of connecting EV charging infrastructure to the power grid in the United States, serving as a starting point for future conversations around these solutions. The solutions noted in this white paper require collaborative efforts among utilities, regulators, and EV charging infrastructure developers to streamline the grid connection process for EV charging infrastructure. They are broadly organized into four areas: 1. Increase data access and transparency: Develop automated load service request tools, integrate hosting capacity and load service request analyses, incorporate EV adoption forecasts, and provide transparency on the processing queue. 2. Improve energization processes and timing: Create fast-track options based on prescreening criteria, provide flexibility or phased approvals in the load service request/interconnection process, build internal knowledge within utilities about EV charging technologies, and provide standardized workforce training. 3. Promote economic efficiency: Right size distribution components to accurately reflect the load requirements of EV charging infrastructure, make proactive investments in grid infrastructure based on EV adoption forecasts and growth projections, and consider energy equity and environmental justice factors such as equitable access to EV charging when planning infrastructure. 4. Improve grid reliability and resilience: Use load management/power control systems (PCS) at EV charging stations, adopt and implement harmonized standards for communication protocols and information models between the EV charging and grid control infrastructure, and address cybersecurity considerations by implementing robust security measures and standards for EV charging infrastructure—with particular emphasis on clarifying the security requirements for the interface to the grid. The objective of the solutions proposed in this white paper is to accelerate the timeline and decrease costs associated with connecting EV charging infrastructure to the grid. Electric utilities, utility regulators, EV charging infrastructure developers, and site hosts will first need to understand which solutions are available in their service territory, and if warranted, which combination of solutions would support their specific needs. Through the successful implementations of solutions at scale detailed here, industry will demonstrate a new and innovative ecosystem where timely deployment and energization of EV charging infrastructure with greater grid resiliency and reliability is a reality.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

EVs@Scale Lab Consortium Bi-Annual Stakeholder Meeting, 17 August 2022, Golden, Colorado [Slides]

The U.S. Department of Energy (DOE) Electric Vehicles at Scale Lab Consortium (EVs@Scale Lab Consortium) is accelerating research to support the establishment of a secure and scalable national network of charging infrastructure. This network will be critical to support tens of millions of light-, medium-, and heavy-duty EVs on American roads by 2030. The EVs@Scale Lab Consortium brings together national laboratories and key stakeholders to conduct infrastructure research and development (R&D) that advances innovations in, and sets unified standards for, high-power and wireless charging. The effort will also develop technologies to integrate vehicle charging with the power grid, and develop cybersecurity measures to protect drivers, vehicles, equipment, and the grid. The first hybrid EVs@Scale Lab Consortium Biannual Stakeholder Meeting was held at NREL on August 17, 2022, to identify research, development, and deployment needs to accelerate technology development for electric vehicles at scale and explore opportunities for collaboration across government, academia, and industry.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Electric Vehicles at Scale (EVs@Scale) Laboratory Consortium

ADVANCED PROPULSION SYSTEMS,POWER TRANSMISSION AND↗

DOE OSTI2023

EVs@Scale Lab Consortium Semi-Annual Stakeholder Meeting

The U.S. Department of Energy (DOE) Electric Vehicles at Scale Lab Consortium (EVs@Scale Lab Consortium) is accelerating research to support the establishment of a secure and scalable national network of charging infrastructure. This network will be critical to support tens of millions of light-, medium-, and heavy-duty EVs on American roads by 2030. The EVs@Scale Lab Consortium brings together national laboratories and key stakeholders to conduct infrastructure research and development (R&D) that advances innovations in, and sets unified standards for, high-power and wireless charging. The effort will also develop technologies to integrate vehicle charging with the power grid, and develop cybersecurity measures to protect drivers, vehicles, equipment, and the grid. The first hybrid EVs@Scale Lab Consortium Semiannual Stakeholder Meeting was held at ANL on September 27-28, 2023, to identify research, development, and deployment needs to accelerate technology development for electric vehicles at scale and explore opportunities for collaboration across government, academia, and industry.

advanced charging and grid interface technologies↗

DOE OSTI2024

2024 Electric Vehicles at Scale Semiannual Stakeholder Meeting

The U.S. Department of Energy (DOE) Electric Vehicles at Scale Lab Consortium (EVs@Scale Lab Consortium) is accelerating research to support the establishment of a secure and scalable national network of charging infrastructure. This network will be critical to support tens of millions of light-, medium-, and heavy-duty EVs on American roads by 2030. The EVs@Scale Lab Consortium brings together national laboratories and key stakeholders to conduct infrastructure research and development (R&D) that advances innovations in, and sets unified standards for, high-power and wireless charging. The effort will also develop technologies to integrate vehicle charging with the power grid, and develop cybersecurity measures to protect drivers, vehicles, equipment, and the grid. The first hybrid EVs@Scale Lab Consortium Semiannual Stakeholder Meeting was held at ANL on September 27-28, 2023, to identify research, development, and deployment needs to accelerate technology development for electric vehicles at scale and explore opportunities for collaboration across government, academia, and industry.

advanced charging and grid interface technologies↗

DOE OSTI2024

High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP): Design Guidelines and Specifications for DC Distribution-Based Charging Hub

Managed under U.S. Department of Energy (DOE)-funded EVs@Scale Consortium, High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project aims to design and develop a high-power, interoperable charging experimental platform to research, develop, and demonstrate the integration and control approaches for a DC distribution-based high-power charging (HPC) system. The eCHIP project addresses the crucial need to design and validate efficient, low-cost, reliable, and interoperable solutions for DC-coupled charging hub ('DC hub' for short). This report explains the design, development, and implementation process of the experimental platform for the DC hub. The utilization of DC distribution holds significant potential for enhancing the operation of an HPC station architecture. However, there are challenges establishing the DC hub, including interoperability, commoditization, distributed energy resource integration, stability, DC protection, and lack of common system level controllers. To address these challenges, a testing setup is required that accommodates commercial off-the-shelf (COTS) products as well as novel, in-house designed solutions to evaluate different use cases at rated power and voltage levels.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

EVs@Scale High Power Charging Pillar

Slide deck assesses a portfolio of EVs, EVSEs, and Fleets that are expected to utilize High Power Charging (>200kW) to understand charging rates, grid impacts, and asset utilization. Provide DOE, project partners, stakeholders, and the public with analysis on the capability of HPC performance of today's charging infrastructure.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

EVSE Cybersecurity and Resilience

Consequence-driven Cybersecurity Analysis for Extreme Fast Charging Electric Vehicle Infrastructure Electric vehicle (EV) development and associated charging infrastructure are expected to advance rapidly. Thirty percent of all global vehicle sales may be EVs and hybrid EVs by 2025, and they will rely on increasingly sophisticated strategies for grid integration. Next-generation EV charging infrastructure is expected to include interconnected renewable resources, such as photovoltaic (PV) arrays and battery storage systems, along with grid-edge devices. Although distributed energy resources (DERs) are useful in several ways, such as peak shaving at high demand times and backup supply for added resilience, the integration of vehicle charging and DERs could create more avenues for cyberattack. Physical and/or remote access to EV charging station components, including charge ports, power electronics, controllers, and local generation (e.g., PV and energy storage) could be paths to cause power fluctuations, leading to altered operations at the charging station, escalated privileges to administrative systems, exfiltration of financial information (including personally identifiable information), and reduced grid stability. One compromised EV supply equipment component can open the door to a variety of exploitable vulnerabilities. Cloud computing and mobile application control have the potential to expand the threat surface to non-repudiation and firmware integrity challenges. Vendor clouds have access to hundreds of chargers, and if compromised, can scale the attack surface exponentially. The high power and voltage levels of xFC infrastructure (e.g., 400 kW at 1000- V DC) increase the hazards and ability to impact the grid and vehicles more than lower-power charging systems. Legacy communications systems and protocols could also put EV infrastructure at risk of cyberattacks requiring a robust patch management process. Communications networks link EVs and chargers to several stakeholders - including charging station operators, grid operators, vendors/manufacturers, and aggregators - who have both physical and network access to share information for control, monitoring, and analytics. Information in these networks that is vulnerable to compromise includes the state of charge, charging duration, payment information, electricity price, and load control. Analyzing and prioritizing these interconnections risks could help address cybersecurity related to data leakage and manipulation.

charging↗

DOE OSTI2025

Spatial Impacts of Electric Vehicle Charging on Power Grid Stability: A Downtown Atlanta Case Study

The rapid increase in electric vehicle (EV) charging demand poses a potential risk to power grid stability, particularly as the spatial distribution of this demand remains underexplored. Existing research often focuses on technical optimization models while overlooking the geographic and human dynamics that affect energy consumption. This study addresses this gap by incorporating mobility data to estimate both building energy use and EV charging demand while also considering geographic factors for a better understanding of grid load. Using agent-based simulations and the Open-Source Distribution System Simulator, the study evaluates the effect of various EV penetration scenarios on grid voltage and unbalance. The results show that, although voltage remains within acceptable limits at lower EV penetration rates, significant voltage drop and unbalance occur as EV penetration exceeds 40%, particularly in residential areas with high charging demand. This study offers a framework for integrating spatial analysis and mobility data in power network simulations, providing insights for future EV infrastructure planning.

Pan, Melrose [ORNL] (ORCID:000000031627448X)↗

DOE OSTI2022

Transforming Energy Through Sustainable Mobility: Expanding Low-Carbon Transportation R&D Solutions

As the nation's premier laboratory for cutting-edge transportation decarbonization research and development solutions, the National Renewable Energy Laboratory (NREL) pioneers the creation and deployment of sustainable mobility technologies and strategies, with a focus on slashing transportation sector greenhouse gas emissions and combatting climate change. Trucks, planes, cargo ships, and other difficult-to-decarbonize vehicles are part of this essential transition for the transportation sector, which is currently the nation's largest source of the greenhouse gas emissions. NREL provides the scientific building blocks needed to spur innovation through multifaceted analysis, research, and engineering. This work acts as a catalyst to help industry bring affordable, high-performance, energy-efficient, and low-emission modes of transport and related infrastructure to market sooner. Our researchers collaborate closely with academic, government, and industry partners to design better batteries, drivetrains, and engines. They develop technologies for high-power charging, thermal management, energy storage, and power electronics. They are also reimagining fuels and combustion while creating sustainable lightweight materials. Unbiased expert guidance - backed by credible data and analysis, tools, and scientific rigor - empowers partners to make informed decisions about sustainable transportation. NREL recognizes that communities with limited mobility options face reduced access to employment opportunities, health care, and education, lowering overall quality of life. Alongside partners, NREL experts are creating transportation solutions that meet community-identified needs and increase mobility equity in historically underserved and overburdened communities. Rather than providing a one-size-fits-all solution, we take an interdisciplinary approach to mobility equity that considers the needs and challenges of diverse groups, maximizing benefits at the individual, community, and societal levels.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

A Unified Design Theory for Multi-Port Polyphase Transformers Enabling Scalable Power-Multiplexed EV Fleet Charging Systems

This paper presents a unified analytical design theory for multi-port polyphase transformers, targeting scalable and isolated high-power Electric Vehicle (EV) fleet charging systems with power multiplexing capability. As fleet electrification accelerates, conventional one-to-one charger architectures face significant challenges in infrastructure cost, peak power demand, and low utilization of installed power electronics. Power-multiplexed charging architectures, which dynamically distribute power from a shared pool of converter modules across multiple vehicles, have emerged as a promising solution. However, such architectures require scalable, isolated multi-port power interfaces capable of routing energy among multiple inputs and outputs, whose design remains complex and dependent on iterative modeling. To address this gap, the proposed theory provides closed-form expressions for self-inductance, leakage inductance, and mutual coupling terms for arbitrary multi-phase, multi-port transformer structures. The formulation enables direct synthesis of isolated multi-input and multi-output resonant converter systems without reliance on geometry-specific finite-element analysis or extensive parameter extraction. This capability is particularly critical for power-multiplexed systems, where modular converter structures must interface with multiple vehicles while maintaining galvanic isolation and flexible power allocation. The effectiveness of the proposed framework is demonstrated through the design of a 360 kW multi-phase system operating over a 700–900 VDC input and 400–1250 VDC output range. PLECS simulation results confirm accurate prediction of system behavior and validate the applicability of the approach to multi-port, power-multiplexed charging scenarios. The proposed method significantly reduces design complexity while enabling scalable, cost-effective, and fully utilized EV fleet charging infrastructure.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗

DOE OSTI2026

Spatially Resolved Domicile Charging Demands for Light-, Medium-, and Heavy-Duty Electric Vehicles in Virginia

The use of plug-in electric vehicles (PEVs) and resulting grid impacts are likely to grow rapidly, and evaluation of optimal smart charge management and grid integration strategies is warranted now. Evaluating distribution grid impacts requires fine-grained models of PEV operations to estimate charging loads across diverse vehicles at high spatial resolution. We propose such a model and consider a high-electrification scenario in Richmond and Newport News, Virginia. Our framework considers four categories of vehicle that are amenable to early aggressive electrification: light-duty passenger vehicles (LDV), trucks and vans with a focus on delivery or other local operations, school buses, and transit buses. These vehicles have a relatively consistent domicile, reducing the need for public charging infrastructure rollout to electrify. We apply a recent LDV model and propose new models for each vocation of medium- and heavy-duty vehicle, leveraging telematics data. We demonstrate our framework in Virginia and find energy demands in the region may total 15 GWh day, with most consumed by LDV. However, considering power demand at high spatial resolution reveals a different trend: LDVs have relatively small peak loads at specific sites (peak site demand around 800 kW) compared to average and high demand medium- and heavy-duty vehicle charging sites (peak site demand around 6,000 kW at a transit bus depot, 1,500 kW at a local freight hub, and 1,000 kW at a school). Our framework yields insights on the relative impacts of each vocation and enables future work to tailor grid integration strategies to each vehicle category.

33 ADVANCED PROPULSION SYSTEMS↗