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DOE OSTI2025

Combined Effects of Electric Vehicle Charging and Rooftop Solar Integration on Voltage Imbalance in Residential Distribution Networks

Residential electric vehicle (EV) chargers, as single phase loads, contribute to unbalanced voltage drops across phases, while rooftop solar systems, as single phase generators, can exacerbate voltage imbalance by causing unbalanced voltage increases. This paper investigates combined effects of residential EV charging and rooftop solar generation on voltage imbalance in residential distribution grids. The study examines these simultaneous impacts using the IEEE 8500-node test system, enhanced with a secondary network to realistically model the EV chargers and rooftop solar integration. To account for the variability and uncertainty in the EV charging loads and solar generation, a Monte Carlo approach is employed to capture and quantify the simultaneous impact of the EV charging and rooftop solar integration. In this approach, multiple influencing factors are considered, including state-of-charge (SOC), maximum charging power levels, and geographic distribution of chargers. The results provide practical insights for utilities and stakeholders, offering expectations for planning and operating strategies that effectively manage the increasing adoption of EVs and solar power while maintaining grid reliability.

Choi, Jongchan [ORNL] (ORCID:000000025952455X)↗

DOE OSTI2025

EVI-EnSitePy (Electric Vehicle Infrastructure – Energy Estimation and Site Optimization Tool in Python) [EVI-X Modeling Suite] [SWR-25-07]

EVI-EnSitePy is a comprehensive agent-based tool designed for the analysis and design of high-power charging sites, encompassing a wide array of site agents including Electric Vehicles (EVs), chargers, energy storage units (ESS), renewable energy resources (DER), and loads. This versatile tool offers diverse functionalities and a modular modeling approach, allowing detailed configuration of agents based on power ratings, port numbers, energy capacities, demand requirements, charger interfaces, and flexibility to customize the tool for project specific goals. By simulating agent interactions and employing various metrics, EVI-EnSitePy enables the assessment of site performance, exploration of energy management systems (EMS), and implementation of innovative EV charging policies. Utilizing EV charge schedules and arrival states, the tool performs thorough charging site simulations, with outputs consisting of agent and site-level power profiles and statistical metrics. Employing a tree graph structure, EVI-EnSitePy supports nested site structures and power distribution modeling. The tool's ability to generate charging schedules deterministically or via stochastic analysis further enhances its versatility. Through its features and capabilities, EVI-EnSitePy offers a powerful platform for informed decision-making in the realm of high-power charging site design and operation.

Jackson, Derek [National Renewable Energy Laborato↗

DOE OSTI2021

Managing Cyber Supply Chain Risk for Renewable Energy Technologies

On July 1, 2021, the U.S. Department of Energy (DOE) Office of Cybersecurity, Energy Security, and Emergency Response (CESER) hosted a virtual workshop facilitated by the National Renewable Energy Laboratory (NREL). Cybersecurity supply chain experts, researchers, and leaders in government and industry came together to share information on current and future challenges in securing emerging technologies and technical architecture. From a cybersecurity perspective, we need to move from a cybersecurity approach that focuses principally on legacy asset owners to one that incorporates more emphasis on end-point device manufacturers and third-party integrators. Cybersecurity for the global digital supply chain for manufacturers of consumer end-point devices—such as smart solar inverters and smart electric vehicle (EV) chargers—will be critical to the future cyber health of the grid.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Intelligent, grid-friendly, modular extreme fast charging system with solid-state DC protection

The development of electric vehicle (EV) charging infrastructure is crucial for the widespread adoption of electric transportation. However, implementing such infrastructure is a complex task that requires consideration of factors such as space limitations, adherence to industry standards, grid capacity, and other technical and policy issues. This project seeks to create a framework for the efficient design of compact medium voltage (MV) extreme fast charging (XFC) stations for EVs. The station design involves the use of a solid-state transformer (SST) that connects to the MV distribution network, delivering power to a shared DC bus. This innovative approach eliminates the need for a step-down transformer to provide low-voltage service by connecting directly to the MV distribution network. Eliminating the low-frequency transformer not only reduces the system footprint and losses but also eliminates inrush currents during grid black-start. Additionally, placing power electronics directly on the distribution system allows for high-bandwidth filtering and power factor correction. The inclusion of a shared DC bus enables multiple charging dispensers and DC storage/generation units to connect, forming a DC microgrid. This setup facilitates power sharing with minimal conversion stages. The project showcases a DC distribution network protected by intelligent solid-state (SS) DC circuit breakers (DCCB) capable of isolating the smallest section of the faulted circuit much faster than existing mechanical solutions.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Public EV Charging Station Site Selection Checklist

The Joint Office of Energy and Transportation (Joint Office) provides technical assistance on planning and implementation of a national network of electric vehicle (EV) chargers and zero-emission fueling infrastructure, as well as zero-emission transit and school buses. There are several considerations that should be addressed when selecting a site for EV charging stations. The following is a checklist to assist with site selection for publicly available EV charging stations.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Deployment priority of public charging speeds for increasing battery electric vehicle usability

To inform charger deployment decisions, this paper aims to understand the potential utilization and deployment priority for public charging infrastructure. A data-driven Cumulative Public Recharging (CPR) model is developed to explore the travel patterns by using 2017 National Household Travel Survey data. Given the daily trip sequence, trip distance, and dwell times, the study examines the daily expected driving range and BEV feasibility under different charging speeds, battery capacity, and charging behaviors. The results suggest that more advanced public chargers increase the daily expected driving range. Home charging is sufficient for most daily short-distance trips while public chargers are still needed for medium- and long-distance trips. Extreme fast charging (xFC) may not be necessary for people with home charging but could be more useful for people without home charging and for urgent charging. In conclusion, xFC becomes even less important to drivers with longer BEV ranges, a finding that contradicts conventional thinking.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

EVs@Scale: NextGen Profiles EVSE Characterization 2025

As part of the U.S. DOE EVs@Scale consortium, the Next-Generation Profiles (NextGen Profiles [NGP]) project presents analysis and results from the characterization of high-power conductive and wireless charging infrastructure. High Power Charging equipment is capable of recharging electric vehicle traction batteries at power levels of 200KW and above. Electric Vehicle Service Equipment (EVSE) characterization involves testing over a wide range of DC charging currents and voltages during nominal and off-nominal conditions. This testing allows for a better understanding of the impact that high-power charging will have on the electric grid. A common set of standard test plans, procedures, and data requirements were applied to the characterization in this document with minor updates and improvements. This report covers all conductive characterization activities performed between October 2024 and September 2025 on the Delta Electronics 350KW Electric Vehicle Charging System, consisting of power cabinet model EIDN-U350KTA01 and dispenser model EIDD-U350SSUUAEG-350.Key Findings include: Output regulation, Efficiency and power factor, Load management, Grid Resilience, Smart Charge Management (SCM) performance, Thermal control system performance, Multi-port simultaneous charging performance, and Selected performance comparisons with other EVSEs characterized in the NextGen Profiles project. Hot and cold temperature testing was not conducted on the Delta 350KW due to laboratory limitations. Future research could include continued testing the Delta hardware under off-nominal temperature conditions including multi-port/multi-session simultaneous charge testing, in addition to collecting data on other high-power conductive chargers to augment.

25 ENERGY STORAGE↗

DOE OSTI2025

Electric Vehicle Supply Equipment (EVSE) Site Assessment Report for the U.S. Army Corps of Engineers Chena Site Near Fairbanks, Alaska

This report presents an analysis of the requirements for charging station installation and electric vehicle operation at the US Army Corps of Engineers - Chena Site, located in a cold weather climate in the Fairbanks North Star Borough, AK. The report includes findings from a site visit, and a detailed electric vehicle (EV) charging site plan with cost estimates. Cost for three 50-ampere pedestal chargers located on the edge of the existing parking lot is estimated at $\$$53,100, and the cost of three 80-ampere chargers is estimated at $\$$89,400. The authors did not assess the cost of a heated garage. The USACE Chena site reaches extreme cold temperatures of -40 Degrees Celsius (-40 Degrees Fahrenheit) and below in a typical winter, often for days on end. Considerations of operating EVs as well as electrical vehicle supply equipment (EVSE) at this site can be applicable to other cold or extremely cold locations. Interviews with EV users in cold climates and a literature review indicated that EVs operate well but have significantly decreased range compared to 21 Degrees Celsius (70 Degrees Fahrenheit) operations. Some strategies such as prewarming the vehicle while it is plugged in and using heated seats and steering wheel instead of cabin heat, can improve cold weather performance. Storing the EV in a garage would mean the battery and cabin are automatically preheated, the battery would not age as rapidly as when the vehicle is stored outside, and problems with charging the vehicle are less likely. Lowest temperate-rated Electric Vehicle Supply Equipment (EVSE), as electric vehicle chargers are known as, are rated to -40 Degrees Celsius (-40 Degrees Fahrenheit), and sometimes malfunction. No EVSE is rated to the temperatures that USACE Chena site experienced for more than a week in winter 2023-4, of -50 Degrees Celsius (-45 Degrees Fahrenheit) and which are typical for the area. If reliability is a must, entities may want to consider a heated garage to minimize potential problems with charging equipment. There is a companion technical report to this titled "Electric Vehicle and Charging Infrastructure Assessment in Cold-Weather Climates: A Case Study of Fairbanks, Alaska" that examines the data on EV and EVSE cold-weather functionality in more detail. (Esparza, Truffer Moudra, and Hodge 2024).

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1987

Ferroresonant flux coupled battery charger

A battery charger for incorporation into an electric-powered vehicle is disclosed. The charger includes a ferroresonant voltage-regulating circuit for providing an output voltage proportional to the frequency of an input AC voltage. A high frequency converter converts a DC voltage supplied, for example, from a rectifier connected to a standard AC outlet, to a controlled frequency AC voltage which is supplied to the input of the ferroresonant circuit. The ferroresonant circuit includes an output, a saturable core transformer connected across the output, and a first linear inductor and a capacitor connected in series across the saturable core transformer and tuned to resonate at the third harmonic of the AC voltage from the high frequency converter. The ferroresonant circuit further includes a second linear inductor connected between the input of the ferroresonant circuit and the saturable core transformer. The output voltage from the ferroresonant circuit is rectified and applied across a pair of output terminals adapted to be connected to the battery to be charged. A feedback circuit compares the voltage across the output terminals with a reference voltage and controls the frequency of the AC voltage produced by the high frequency converter to maintain the voltage across the output terminals at a predetermined value. The second linear inductor provides a highly reactive load in the event of a fault across the output terminals to render the charger short-circuit proof.

McLyman, Colonel W. T.↗

DOE OSTI2023

Demand-Side Grid (dsgrid) TEMPO Light-Duty Vehicle Charging Profiles v2022

Simulated hourly electric vehicle charging profiles for light-duty household passenger vehicles in the contiguous United States, 2018-2050. Profiles are differentiated by scenario, county, household and vehicle types, and charging type. Data was produced in 2022 using the Transportation Energy & Mobility Pathway Options (TEMPO) model and published in demand-side grid (dsgrid) toolkit format. Data are available for three adoption scenarios: "AEO Reference Case", which is aligned with the U.S. EIA Annual Energy Outlook 2018 (linked below), "EFS High Electrification", which is aligned with the High Electrification scenario of the Electrification Futures Study (linked below), and "All EV Sales by 2035", which assumes that average passenger light-duty EV sales reach 50% in 2030 and 100% in 2035. The charging shapes are derived from two key assumptions of which data users should be aware: "ubiquitous charger access", meaning that drivers of vehicles are assumed to have access to a charger whenever a trip is not in progress, and "immediate charging", meaning that immediately after trip completion, vehicles are plugged in and charge until they are either fully recharged or taken on another trip. These assumptions result in a bounding case in which vehicles' state of charge is maximized at all times. This bounding case would minimize range anxiety, but is unrealistic from the point of view of both electric vehicle service equipment (EVSE) (i.e., charger) access, and plug-in behavior as it can result in dozens of charging sessions per week for battery electric vehicles (BEVs) that in reality are often only plugged in a few times per week.

Array↗

DOE OSTI2022

A PCB-Embedded 1.2 kV SiC MOSFET Half-Bridge Package for a 22 kW AC–DC Converter

This article presents the design and analysis of a double-side-cooled printed circuit board (PCB) embedded silicon carbide (SiC) MOSFET half-bridge package with low loop inductances and an integrated gate driver. The 1.2 kV SiC MOSFET dies used in the half-bridge package are embedded in the PCB using AT&S's patented technique. The dies are cooled and electrically connected to traces in the PCB through copper-filled microvias. The design methodology accounts for both electrical and thermal performance, limiting the power-loop inductance to 2.3 nH and the maximum package temperature to less than the 175 °C limit. The integration of the gate drive circuitry allows for a high power density and 2.2 nH gate-loop inductances. At 0.12 K/W, the measured junction-to-case thermal resistance with double-sided cooling is 57% lower than that of a TO-247 package. Under similar operating conditions, the PCB-embedded half-bridge package also achieves a 5.6 times lower voltage overshoot and a 0.5% higher peak efficiency than a TO-247-based half-bridge. This article reports the first demonstration of PCB-embedded 1.2 kV SiC MOSFET packages in buck, boost, and ac–dc converters. Furthermore, the prototype three-phase ac–dc converter for an electric vehicle on-board charger is composed of six PCB-embedded half-bridge packages and achieves an efficiency of 98.2% and a power density of 182 W/in 3 .

42 ENGINEERING↗

DOE OSTI2025

EVI-LOCATE User Manual

One of the longest stages in the deployment of electric vehicle supply equipment (EVSE) is the initial planning of the infrastructure itself. Engineers and fleet experts from the National Renewable Energy Laboratory (NREL) have supported dozens of charging infrastructure site plans over the past couple decades, including the generation of site schematics, determinations of electric capacity, and estimates for likely costs. As the market for electric vehicles (EVs) has matured, this approach should no longer require a time and personnel intensive process. In order to shorten the time taken to develop site plans and cost estimates, NREL developed a tool that fleet managers, facility managers, electricians, EVSE installers, and members of the public can use to develop initial schematics and ballpark pricing for charging station installations. The Electric Vehicle Infrastructure - Locally Optimized Charger Assessment Tool and Estimator (EVI-LOCATE) provides a structured and consistent way for users to enter information about their planned EVSE project in a relatively simple web-based format. EVI-LOCATE then calculates electrical equipment capacity, wiring runs, and project costs. It produces a site diagram optimized around surface characteristics with differential trenching costs for softscape such as grass compared to hardscape such as asphalt that can be adjusted by users in the tool. It also stores the resulting site plans and costs in a dashboard for access at a later date, including plan revisions if necessary. This document guides users through the EVI-LOCATE screens and associated questions. It contains tip text boxes throughout on how best to interface with the tool and find additional information or context. The appendices contain the assumptions and calculations underpinning the tool. Much of the information for EVI-LOCATE was gathered through industry engagements with EVSE installers, invoices from completed EVSE installations, Gordian's RS Means construction data, and the General Services Administration blanket purchase agreement for EVSE. For a visual tutorial of the tool, users can watch EVI-LOCATE Step-by-Step Video. The tool itself is available at https://evi-locate.nrel.gov.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Electric Vehicle Charging Infrastructure Trends from the Alternative Fueling Station Locator (Third Quarter 2023)

Electric vehicle (EV) charging infrastructure continues to rapidly change and grow. Using data from the U.S. Department of Energy's (DOE's) Alternative Fueling Station Locator, this report provides a snapshot of the state of EV charging infrastructure in the United States in the third calendar quarter of 2023 (Q3 2023) by charging level, network, and location. Additionally, this report measures the current state of charging infrastructure compared to the infrastructure requirement scenario outlined in the National Renewable Energy Laboratory (NREL) report, The 2030 National Charging Network: Estimating U.S. Light-Duty Demand for Electric Vehicle Charging Infrastructure. This information is intended to help transportation planners, policymakers, researchers, infrastructure developers, and others understand the rapidly changing landscape of EV charging infrastructure. This is the fifteenth report in a series. Reports from previous quarters can be found in the Alternative Fuels Data Center (AFDC) and NREL publication databases, as well as the AFDC Charging Infrastructure Trends page (https://afdc.energy.gov/fuels/electricity_infrastructure_trends.html).

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Electric Vehicle Charging Infrastructure Trends from the Alternative Fueling Station Locator: Fourth Quarter 2023

Electric vehicle (EV) charging infrastructure continues to rapidly change and grow. Using data from the U.S. Department of Energy's (DOE's) Alternative Fueling Station Locator, this report provides a snapshot of the state of EV charging infrastructure in the United States in the fourth calendar quarter of 2023 (Q4 2023) by charging level, network, and location. Additionally, this report measures the current state of charging infrastructure compared to the infrastructure requirement scenario outlined in the National Renewable Energy Laboratory (NREL) report, The 2030 National Charging Network: Estimating U.S. Light-Duty Demand for Electric Vehicle Charging Infrastructure. This information is intended to help transportation planners, policymakers, researchers, infrastructure developers, and others understand the rapidly changing landscape of EV charging infrastructure. This is the sixteenth report in a series. Reports from previous quarters can be found in the Alternative Fuels Data Center (AFDC) and NREL publication databases, as well as the AFDC Charging Infrastructure Trends page (https://afdc.energy.gov/fuels/electricity_infrastructure_trends.html).

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Electric Vehicle Charging Infrastructure Trends from the Alternative Fueling Station Locator: Second Quarter 2024

Electric vehicle (EV) charging infrastructure continues to rapidly change and grow. Using data from the U.S. Department of Energy's (DOE's) Alternative Fueling Station Locator, this report provides a snapshot of the state of EV charging infrastructure in the United States in the second calendar quarter of 2024 (Q2 2024) by charging level, network, and location. Additionally, this report measures the current state of charging infrastructure compared to the infrastructure requirement scenario outlined in the National Renewable Energy Laboratory (NREL) report, "The 2030 National Charging Network: Estimating U.S. Light-Duty Demand for Electric Vehicle Charging Infrastructure" (https://www.nrel.gov/docs/fy23osti/85654.pdf). This information is intended to help transportation planners, policymakers, researchers, infrastructure developers, and others understand the rapidly changing landscape of EV charging infrastructure. This is the 18th report in a series. Reports from previous quarters can be found in the Alternative Fuels Data Center (AFDC) and NREL publication databases, as well as the AFDC Charging Infrastructure Trends page (https://afdc.energy.gov/fuels/electricity_infrastructure_trends.html).

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Impact of electric vehicle charging on the power demand of retail buildings

As electric vehicle penetration increases, charging is expected to have a significant impact on the grid. Electric vehicle charging stations will greatly affect a building site's power demand, especially with the onset of fast charging with power levels as high as 350 kW per charger. Here, we assess how electric vehicle charging stations would impact a retail big box grocery store, exploring numerous station sizes, charging power levels, and utilization factors in various climate zones and seasons. We measure the effect of charging by assessing changes in monthly peak power demand, electricity usage, and annual electricity bill, computed using three distinct rate structures. We find that an electric vehicle station has the potential to dwarf a big box building's power demand if behind the same meter, increasing monthly peak power demand at the site by over 250%. Cold-climate areas paired with rate structures incorporating high demand charges are most susceptible for significant changes to the annual electricity bill, with increases as high as 88%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Electric Vehicle Charging Infrastructure Trends from the Alternative Fueling Station Locator: First Quarter 2024

Electric vehicle (EV) charging infrastructure continues to rapidly change and grow. Using data from the U.S. Department of Energy's (DOE's) Alternative Fueling Station Locator, this report provides a snapshot of the state of EV charging infrastructure in the United States in the first calendar quarter of 2024 (Q1 2024) by charging level, network, and location. Additionally, this report measures the current state of charging infrastructure compared to the infrastructure requirement scenario outlined in the National Renewable Energy Laboratory (NREL) report, "The 2030 National Charging Network: Estimating U.S. Light-Duty Demand for Electric Vehicle Charging Infrastructure" (https://www.nrel.gov/docs/fy23osti/85654.pdf). This information is intended to help transportation planners, policymakers, researchers, infrastructure developers, and others understand the rapidly changing landscape of EV charging infrastructure. This is the 17th report in a series. Reports from previous quarters can be found in the Alternative Fuels Data Center (AFDC) and NREL publication databases, as well as the AFDC Charging Infrastructure Trends page (https://afdc.energy.gov/fuels/electricity_infrastructure_trends.html).

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Thermal Evaluation of CCS and NACS Reference Devices and Adapters

It is important for manufacturers of electric vehicle charging connectors, inlets, and adapters to understand the thermal performance of their devices. Various standards, such as SAE J1772, SAE J3400, IEC 62196, UL 2251, and UL 2252, list temperature limits that charging hardware needs to meet. However, there are currently very limited standardized reference devices against which to measure connector performance, and those that do currently exist generally serve charging currents less than 500A. This can make determining whether a charging connector meets the appropriate temperature limits difficult. Additionally, as automakers and charging station suppliers transition from the SAE J1772 CCS charging standard to SAE J3400 NACS, a number of CCS-to-NACS and NACS-to-CCS adapters are entering the market. These devices are being produced both by well-known automakers/equipment OEMs and lesser-known third-party suppliers, across a wide range of price points and construction qualities. Though SAE J3400/1 and UL 2252 lay out standards for adapter construction, performance and overtemperature response, there is no guarantee that any particular adapter will follow these standards and react to overtemperature events appropriately. This work addresses these issues by developing and evaluating a set of CCS and NACS reference inlet devices to validate the performance of charging connectors in the 500-800A range. The work also evaluates the performance of multiple NACS-to-CCS and CCS-to-NACS charging adapters with respect to UL 2252 temperature limits and SAE J3400/1 overtemperature signaling criteria.

33 ADVANCED PROPULSION SYSTEMS↗