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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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At least 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Optimizing Long Term Hydrogen Fueling Infrastructure Plans on Freight Corridors for Heavy Duty Fuel Cell Electric Vehicles

The development of a future hydrogen energy economy will require the development of several hydrogen market and industry segments including a hydrogen based commercial freight transportation ecosystem. For a sustainable freight transportation ecosystem, the supporting fueling infrastructure and the associated vehicle powertrains making use of hydrogen fuel will need to be co-established. This paper develops a long-term plan for refueling infrastructure deployment using the OR-AGENT (Optimal Regional Architecture Generation for Electrified National Transportation) tool developed at the Oak Ridge National Laboratory, which has been used to optimize the hydrogen refueling infrastructure requirements on the I-75 corridor for heavy duty (HD) fuel cell electric commercial vehicles (FCEV). This constraint-based optimization model considers existing fueling locations, regional specific vehicle fuel economy and weight, vehicle origin and destination (OD), vehicle volume by class and infrastructure costs to characterize in-mission refueling requirements for a given freight corridor. The authors applied this framework to determine the ideal long term public access locations for hydrogen refueling (constrained by existing fueling stations and dispensing technology), the minimal viable cost to deploy sufficient hydrogen fuel dispensers, and associated equipment, to accommodate a growing population of hydrogen fuel cell trucks. So the framework discussed in this paper can be expanded and applied to additional electrified powertrains as well as a larger interstate system, expanded regional corridor, or other transportation networks.

08 HYDROGEN↗
DOE OSTI2024

Grid-Constrained Electric Vehicle Fast Charging Sites: Battery-Buffered Options

This case study summarizes recent Joint Office of Energy and Transportation technical assistance work performed by the National Renewable Energy Laboratory which involved helping a state department of transportation analyze the feasibility of a battery energy storage system solution at a grid-constrained EV charging location.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Fire Protection Engineering Technical Report for Electric Vehicles and Lithium-Ion Batteries

This fire protection engineering technical report discusses and presents the properties, data, and safety of select lithium-ion batteries. Lithium-ion batteries have increased in usage and a fire scenario analysis must be created for each situation where they may be introduced in buildings to determine the risk associated if a battery failure were to occur.

25 ENERGY STORAGE↗
DOE OSTI2024

Survey and Gap Prioritization of U.S. Electric Vehicle Charge Management Deployments

The goal of this study was to survey and characterize the scope of current technical and programmatic knowledge pertaining to EV charge management technologies and practices in the US and relevant international jurisdictions. This characterization of existing field demonstrations and knowledge derived were used to determine gaps in the SCM demonstration landscape. Addressing these gaps through research and demonstration could increase confidence in the U.S. that load management and EV charge control could achieve overarching societal benefits. A survey of charge management deployments and input from stakeholders was completed to determine the state-of-the-art of smart charge management (SCM) where SCM is defined as controlling the amount of power exchanged between chargers and EVs to meet customers' charging needs while also responding to external power demand or pricing signals to provide load management, resilience, or other benefits to the customer and electric grid. The survey was the basis of the gap analysis in this report and determines which areas are well understood, with high confidence, and which areas need further investigation. Existing examples of EV charge management are characterized here to determine aspects that are ready for widespread deployment and have been demonstrated in the field. These include demonstration studies, pilots, programs, and EV-specific tariffs. In all, 110 examples of charge management were characterized. The data sources were public literature and utility filings as well as targeted interviews. In addition, 43 interviews with stakeholders were conducted with a consistent set of questions used in each interview. This study prioritized gaps in demonstrated SCM capabilities based on 1) Urgency of the particular use-case to offset traditional grid assets, 2) Impact, extensibility, and scaling of results across the entire spectrum of 3000+ utility service territories including projected technical and market potential for a given grid service, and 3) Value of federal funding in addressing the gap, including potential to leverage and/or add scope to existing field demonstrations funded by other non-federal funding mechanisms.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Lessons Learned from the Clean Energy to Communities (C2C) Peer-Learning Cohort Incorporating Community Priorities into Electric Vehicle Plans and Projects

The National Renewable Energy Laboratory (NREL), with support from World Resources Institute (WRI), designed and led a six-month peer-learning cohort from January through July 2024 on "Enhancing Resilience at Critical Facilities through Solar, Storage, and Microgrids" as part of the U.S Department of Energy's Clean Energy to Communities (nrel.gov/c2c) (C2C) program. Representatives from 15 municipalities, municipal utilities, colleges, and Tribes from across the United States participated in monthly workshops covering best practices for planning and deploying local resilience projects. This document shares key takeaways, lessons learned, and resources from the cohort including key steps that can be taken to help entities design effective community engagement processes around clean mobility.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2025

Managing Increased Electric Vehicle Shares on Bulk Power Systems

The convergence of transportation electrification, other load growth, and the integration of many power sector technologies presents a complex planning problem requiring realistic, region-specific modeling and analysis to ensure the power system can support new loads quickly and affordably.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Optimized Highly Efficient SSCB Using Organic Substrate Packaging for Electric Vehicle Applications

Solid State Circuit Breakers (SSCBs) are an attractive protection solution for their arcless current interruption and fast actuation speeds over mechanical breakers. This paper proposes a Bidirectional SSCB (BSSCB) with a thermally defined and digitally controlled current time profile for fault protection in EV and other low-voltage DC systems. The paper proposes an organic packaging approach utilizing flex circuitry to develop a reliable, cost-effective power module for BSSCBs. The paper studies transient heat transfer in the power modules using finite element analysis (FEA). An RC themal ladder network is extracted to define a fusing curve. To demonstrate and verify the design, a 1kV/50 A SiC MOSFET BSSCB prototype is fabricated and tested, having a power density of 60 W/cm3 and 4x reduction in form factor over presently researched breakers. Also, given are results for 750 V/150 A operation showing interruption in 2.4 μs.

organic power packaging↗
DOE OSTI2020

Integrating Electric Vehicle Charging Infrastructure into Commercial Buildings and Mixed-Use Communities: Design, Modeling, and Control Optimization Opportunities: Preprint

This paper discusses modeling and field studies of controlled EV charging that have been performed with the goal of minimizing requirements for infrastructure upgrades, minimizing building peak demand charges, and maximizing the use of on-site generation. We present a large-scale workplace charging pilot of a demand-controlled scheduled EV charging system with over 250 active daily commuters, successfully demonstrating management of aggregate charging power to avoid new infrastructure investments, mitigate peak demand charges, and provide cost-effective workplace charging to users. In addition to understanding opportunities for demand management, integrating these controllable loads into the energy modeling process for new buildings will also be necessary. This paper then presents an example energy modeling process that evaluates the potential effects of EV charging on building load profiles and infrastructure requirements for a mixed-use community. Finally, we discuss an illustration of how EV charging can be controlled to be synergistic with other building loads and distributed generation.

buildings↗
DOE OSTI2026

Cost of convenience in long-dwell public electric vehicle charging

This paper presents a comprehensive methodology for quantifying trade offs between the cost of charging at public Level-2 charging stations and the inconvenience of using those stations. The paper also includes a methodology for generating synthetic travel itineraries of tens of thousands of drivers and for sizing and placing charging infrastructure to support those itineraries. Inconvenience is quantified by a weighted sum of the time a driver spends traveling between their intended destination and the charging station; weights are derived from the activity interrupted by the driver’s need to move their car. We demonstrate a trade off between cost of charging and inconvenience by varying how far away from their destination drivers are willing to charge. Our results demonstrate the importance of access to stations and suggest that other methods for increasing access, such as increasing the spatial density of stations, could significantly impact charging cost and inconvenience. Moreover, average energy cost may be reduced by introducing managed charging, which also affects inconvenience. The framework presented here can be used to evaluate the overlapping effects of both access and charge management. Furthermore, the framework can be easily extended to include additional factors such as capital costs, enabling thorough evaluation and planning of regional Level-2 charging networks.

32 - ENERGY CONSERVATION, CONSUMPTION, AND UTILIZA↗
DOE OSTI2023

Recommendations for Minimum Required Error Codes for Electric Vehicle Charging Infrastructure

OCPP protocol manages the interaction between the EVSE and its respective back-end communication network. It plays a pivotal role in both error reporting and troubleshooting, carried out primarily through the CSMS. OCPP defines both standard error codes and a flexible framework for creating and communicating custom error codes. The OCPI protocol orchestrates the communication between different backhaul communication networks, incorporating the exchange of error codes. These error codes are instrumental in pinpointing and rectifying issues that can surface prior to, during, or after charging operations, fortifying the reliability and resilience of the EV charging infrastructure. The flexibility offered by the OCPP and OCPI frameworks through the introduction of custom error codes also creates its own set of challenges. While the integration of custom error codes allows for enhanced granularity, it also introduces inconsistencies and fragmentation within the overarching diagnostic reporting system. To address the challenges with custom error codes this report proposes a set of Minimum Required Error Codes (MRECs) for streamlined error reporting, interpretability, and diagnostics. Recommendations in this report are based on independent analysis of custom error codes from multiple stakeholders within the EV charging ecosystem. For better error resolution, this report also assigns one or more entities responsible for the resolution of every mentioned error code. Finally, a functional classification for each mentioned error code is also identified to describe the nature of the error. In summary, the purpose of this document is to simplify the troubleshooting process and increase charging reliability for all EV users. This report serves as a recommendation for industry stakeholders, encouraging a unified methodology to define, transmit, and interpret common error codes.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Complementary Electrolyte Design for Li Metal Batteries in Electric Vehicle Applications

In this report a complementary electrolyte system with 0.8 M lithium bis(fluorosulfonylimide) (LiFSI) salt and 2 wt % lithium perchlorate (LiCLO4) additive in fluoroethylene carbonate (FEC)/ethyl methyl carbonate (EMC) solution enables not only stable cycling of lithium metal batteries (LMBs) with practical loading (<30 μm lithium anode, cathode loading > 4 mAh/cm 2 ) but also outstanding degradation stability toward the end of cycle life when compared to the conventional electrolyte. Although the use of LiFSI salt can increase the electrolyte conductivity and lengthen the cycle life of LMBs, the aged lithium anode morphology formed by the sacrificial decomposition of LiFSI is highly porous, leading to an abrupt cell capacity drop toward the end of cycling. Moreover, the inability to stop aluminum corrosion by the LiFSI-based electrolyte also causes cracking of the cathode tab during prolonged cycling. It is observed that a highly porous aged lithium consumed electrolyte at a higher rate, leading to the dry-out of electrolyte solvents. On the contrary, dense aged lithium anode morphology increased the localized current applied on the lithium, causing the formation of lithium dendrite. Thus, porosity control is the key to enhance battery performance. In this complementary system, LiClO 4 was introduced as an advanced additive to not only improve the capacity retention rate but also mitigate the abrupt capacity drop toward the end of cycle life because LiClO 4 acted as a pore astringent reducing the porosity of the aged lithium metal anode to the desired level. Moreover, the addition of LiClO 4 can also suppress the AI corrosion, allowing stable high-voltage cycling of LMBs. The synergistic effect of combining LiFSI salt and a LiClO 4 additive leads to an electrolyte system that can facilitate the application of high-energy LMBs with practical electrode loading.

25 ENERGY STORAGE↗
NASA NTRS1983

Integral inverter/battery charger for use in electric vehicles

The design and test results of a thyristor based inverter/charger are discussed. A battery charger is included integral to the inverter by using a subset of the inverter power circuit components. The resulting charger provides electrical isolation between the vehicle propulsion battery and ac line and is capable of charging a 25 kWh propulsion battery in 8 hours from a 220 volt ac line. The integral charger employs the inverter commutation components at a resonant ac/dc isolated converter rated at 3.6 kW. Charger efficiency and power factor at an output power of 3.6 kW are 86% and 95% respectively. The inverter, when operated with a matching polyphase ac induction motor and nominal 132 volt propulsion battery, can provide a peak shaft power of 34 kW (45 ph) during motoring operation and 45 kW (60 hp) during regeneration. Thyristors are employed for the inverter power switching devices and are arranged in an input-commutated topology. This configuration requires only two thyristors to commutate the six main inverter thyristors. Inverter efficiency during motoring operation at motor shaft speeds above 450 rad/sec (4300 rpm) is 92-94% for output power levels above 11 KW (15 hp). The combined ac inverter/charger package weighs 47 kg (103 lbs).

Thimmesch, D.↗
DOE OSTI2023

Stress characterization for friction-stir-welded electric vehicle battery trays with application of neutron diffraction

The battery tray is an essential component that protects and controls battery-cell temperatures in electric and plug-in hybrid vehicles. The functional stress limit of the battery tray heavily depends on the residual stress acquired from the manufacturing process. Consequently, exceeding the stress limit of the battery tray during operation could compromise the battery-cell banks and may risk the vehicle's safety. Hence, understanding residual stress formation is vital for design and safety concerns. Here, in the current study, AA 6061-plates were friction stir welded to an A365 high-pressure die-cast battery tray to create sealed coolant channels in the battery tray. However, this multi-material lap friction stir weld introduces residual stress into the battery tray, resulting in distortion. This distortion was mitigated using burnishing or coining operations, though straightening the battery tray had initially unknown effects on the residual stress. Therefore, neutron diffraction was utilized to characterize residual stresses after straightening. The results indicate that the friction stir welding (FSW) operation generated residual stresses exceeding the yield strength of the material, consequently deforming the battery tray by ±3 mm from the pre-weld geometry. The burnishing operation reduced the residual stresses below the material's yield strength while restoring the tray to within ±0.75 mm of the pre-weld geometry. Similarly, the coining operation restored the battery tray to within ±0.75 mm of the pre-weld geometry, however, increasing the number of locations where the residual stress exceeds the yield strength of the material.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Multi-State Transportation Electrification Impact Study: Preparing the Grid for Light-, Medium-, and Heavy-Duty Electric Vehicles

Recent U.S. Environmental Protection Agency (EPA) notices of proposed rulemakings for GHG emissions standards for light-, medium-, and heavy-duty on-road vehicles would accelerate ongoing advancements already happening in the industry because of private investment, consumer demand, state-level policies, and federal incentives. As the EPA finalizes these regulations, questions persist regarding the cost of the requisite charging infrastructure and associated upgrades to the nation's electric grid. With support from the U.S. Department of Energy, U.S. Joint Office of Energy and Transportation, and the EPA, a multidisciplinary team conducted a Multi-State Transportation Electrification Impact Study that quantitatively assesses the incremental investment necessary to enable the levels of vehicle electrification expected to be induced by pending EPA regulations and to estimate the potential value of deferred investments in electric distribution infrastructure stemming from proactive vehicle-grid integration planning and deployment. This study finds the simulated incremental capital cost of charging infrastructure (including grid upgrades) to be at least 2.5 times smaller than the lifetime net benefits of vehicle electrification (including fuel savings but excluding the value of avoided emissions). Additionally, the incremental distribution grid upgrade cost of the EPA Action-Unmanaged scenario was found to be approximately 3% of existing utility distribution system investments (on an annual basis). Finally, the potential for managed charging to defer distribution grid upgrades was found to be significant with costs found to decrease from $2.3 billion to an incremental cost of $1 billion across five states in the Action-Managed scenario (relative to the No Action-Unmanaged scenario).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS1981

Electronically commutated dc motors for electric vehicles

A motor development program to explore the feasibility of electronically commutated dc motors (also known as brushless) for electric cars is described. Two different design concepts and a number of design variations based on these concepts are discussed. One design concept is based on a permanent magnet, medium speed, machine rated at 7000 to 9000 rpm, and powered via a transistor inverter power conditioner. The other concept is based on a permanent magnet, high speed, machine rated at 22,000 to 26,000 rpm, and powered via a thyristor inverter power conditioner. Test results are presented for a medium speed motor and a high speed motor each of which have been fabricated using samarium cobalt permanent magnet material.

Maslowski, E. A.↗
DOE OSTI2020

Promises and Challenges of Next-Generation “Beyond Li-ion” Batteries for Electric Vehicles and Grid Decarbonization

The tremendous improvement in performance and cost of lithium-ion batteries (LIBs) have made them the technology of choice for electrical energy storage. While established battery chemistries and cell architectures for Li-ion batteries achieve good power and energy density, LIBs are unlikely to meet all the performance, cost, and scaling targets required for energy storage, in particular, in large-scale applications such as electrified transportation and grids. The demand to further reduce cost and/or increase energy density, as well as the growing concern related to natural resource needs for Li-ion have accelerated the investigation of so-called "beyond Li-ion" technologies. In this review, we will discuss the recent achievements, challenges, and opportunities of four important "beyond Li-ion" technologies: Na-ion batteries, K-ion batteries, all-solid-state batteries, and multivalent batteries. Here, the fundamental science behind the challenges, and potential solutions toward the goals of a low-cost and/or high-energy-density future, are discussed in detail for each technology. While it is unlikely that any given new technology will fully replace Li-ion in the near future, "beyond Li-ion" technologies should be thought of as opportunities for energy storage to grow into mid/large-scale applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Rugged WBG Devices and Advanced Electric Machines for High Power Density Automotive Electric Vehicles

This work explored two very important approaches for supporting transportation electrification and reducing dependence on imports of critical materials. In the first task, several novel electric machine architectures with low rare earth metal content were compared analytically, then experimentally to verify their performance. Rare earth metals are imported largely from China and are widely used in many clean energy systems such as wind turbines and EV motors. Reducing our dependence on this critical material is an important objective for ensuring our independence and continued economic prosperity. In the second task, a GaN based inverter for EV inverters was developed to demonstrate the suitability of that wide bandgap semiconductor device in this important application.

42 ENGINEERING↗