Protection of Megawatt-Scale DC Fast Charging Infrastructure for Heavy-Duty Vehicles: Ultra-Fast DC Breaker Development, Testing, and Future Roadmap
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Rahman, Md Rakib-Ur↗
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Traction Inverter Integrated On-Board DC Fast Charging through Partial Power Processing
This paper introduces an innovative on-board integrated DC charging approach through partial power processing (PPP) in a traction inverter system. The proposed system, incorporating a series-connected partial power dual-active-bridge (DAB) converter, efficiently regulates the DC link voltage to achieve an optimal bus voltage for traction operation across a wide speed and torque range. Leveraging partial and bidirectional power processing, the battery current during charging is precisely regulated without the need for external DC-DC charging equipment, ensuring seamless integration to a DC hub with different voltage levels. This advanced integration also endows the system with bidirectional power exchange capability to/from the external DC hub, i.e., vehicle-to-DC (V2DC).
DAB↗
A Solid-State Technology Enabled Compact, Modular Design to Reduce DC Fast Charging Cost and Footprint
The goal of this program was to develop a solid-state transformer (SST) capable of supplying 800 V DC to electric vehicle charging dispensers when connected to a 13.2 kV rms line-line, 3-phase AC grid input. The power level as tested was 1.3 MW.
33 ADVANCED PROPULSION SYSTEMS↗
DC Fast Charging Test Procedures
This report has been drafted as an initial effort to develop a standardized test procedure for DCFC for LD EVs. The proposed test procedures are designed to be time-efficient, aligned with EV discharge tests, and practical to implement, thereby minimizing the testing and computational efforts required by OEMs and testing authorities.
33 ADVANCED PROPULSION SYSTEMS↗
Refining Control, Charging, and Battery Chemistry for CO 2 e Savings in Heavy-Duty Off-Road Plug-In Series Hybrid
With current and future regulations continuing to drive reductions in carbon dioxide equivalent (CO 2 e) emissions in the on-road industry, the off-road industry is also likely to be regulated for fuel and CO 2 e savings. This work focuses on converting a heavy-duty off-road material handler from a conventional diesel powertrain to a plug-in series hybrid, achieving a 49% fuel reduction and 29% CO 2 e reduction via simulation. Control strategies were refined for energy savings, including a regenerative braking strategy to increase regenerative braking and a load-following hydraulic strategy to decrease electrical energy consumption. The load-following hydraulic control shuts off the hydraulic electric machine when it is not needed—an approach not previously seen in a load-sensing, pressure-compensated system. Furthermore, these strategies achieved a 24.1% fuel savings, resulting in total savings of 61% in fuel and 41% in CO 2 e in the plug-in series compared to the conventional machine. Beyond control strategies, this study evaluated battery chemistry and charging strategy refinements for total cost of ownership (TCO) and lifetime CO 2 e. LFP batteries emerged as the most cost-effective and least emitting due to their longer lifespan, which reduced replacement frequency. Charging comparisons showed that Level 2 charging (L2C) typically resulted in lower TCO but higher lifetime CO 2 e than DC fast charging (DCFC). DCFC costs were heavily influenced by local demand charges, and DCFC emissions were heavily influenced by local grid emissions.
33 ADVANCED PROPULSION SYSTEMS↗
Charging Hub Scenario Sheet Screenshot
The Excel-based CHECT tool estimates the LCOC ($/kWh) by charger type (Level 1, Level 2, and DC fast charging) for a given charging hub scenario. CHECT requires users to input certain charging hub scenario parameters, including the number of chargers, daily utilization, and charger replacement frequency by charger type. Additional inputs such as the charging schedule, local utility rates, capital/operational costs, and financial inputs can be customized by the user, or the tool can generate results using appropriate default values from literature for the charging hub scenario and service location(s). Using the above inputs, CHECT performs a robust techno-economic analysis to generate the LCOC by charger type, broken down by cost category (e.g., capital, operational, utility, taxes) for various combinations of charging hub types (multiunit dwelling or public) and ownership models (residential, utility, or private company). It also outputs the annual discounted cash flows and determines the most sensitive input variables. In addition, the tool allows users to easily compare the LCOC across various ownership models or across different states.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Rural EVSE Planning and Analysis
The dataset includes detailed anonymized public charging station usage from several rural stations on the ChargePoint and Shell Recharge Solutions (formerly Greenlots) networks situated in and around Athens, Ohio, a rural Appalachian community. Both Level 2 and DC fast charging stations are represented. Historical data in the set date back to 2019; additional data will be uploaded semiannually until the project's completion in 2023. Each charging session recorded includes information on date and time, location, charging station level, session duration, energy delivered, and fuel savings.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Coordinated Thermal Safety Attack and Defense on EV Battery Management Systems
Battery temperature sensor and battery current sensor data which are key sensing inputs to the Battery Management Controllers in electric vehicles, are vulnerable to possible cyber/ physical manipulation due to known vulnerabilities inherited from CAN bus technology that is used for in-vehicle communications between electronic control units that transfer sensing and control data. In this paper, we first create a simulation that enables us to evaluate impact of cyber physical attacks on electric vehicle battery management system in a controlled environment that violates thermal safety. Specifically, we emulate a Level 3 - DC fast charging system with SAE J1772/CCS, integrated with standard charging controls and thermal safety controls on EVs, and various sensing data flows. Second, we propose a coordinated current and battery temperature attack that has crippling economic, and safety impacts. Third, we quantify the usability, economic and safety impacts of such attacks as a function of the extent of data manipulation. Finally, we propose a physics model driven detection technique to detect presence of such attacks.
25 ENERGY STORAGE↗
Underlying Data for the EVI-RoadTrip Web Tool
The dataset contains simulation-based charging infrastructure outputs that are visualized on the EVI-RoadTrip webtool. The outputs are aggregated to lower spatial resolution (e.g., state-level, corridor-level).
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Load Profiles Data for the EVI-RoadTrip Web Tool
The dataset contains EVI-RoadTrip outputs, minute-by-minute load profiles in kW for each station in the simulation based on assumed utilization and network density. The load profiles are aggregated to lower spatial resolution (e.g., state-level, corridor-level) by summation of all station loads associated with the respective geography. This results in a load profile for each scenario that summarizes the corridor's, state's, or county's load profile in minute-level resolution.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
EVI-X Electric Vehicle Infrastructure Toolbox
The Electric Vehicle Infrastructure Toolbox offers resources for estimating charging infrastructure needs and associated electrical demands based on user-defined electric vehicle adoption scenarios. For more information and additional resources, see the full EVI-X modeling suite of electric vehicle charging infrastructure analysis tools.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
ELECTRIFICATION OF A HEAVY-DUTY OFF-ROAD MATERIAL HANDLER: ENERGY SAVINGS AND EMISSION REDUCTIONS
Federal regulations are driving the adoption of electrification technologies to reduce carbon dioxide equivalent (CO2e) emissions, a metric that quantifies the global warming potential of various greenhouse gases in terms of carbon dioxide (CO2). Although no specific CO2 regulations exist for heavy-duty off-road machines, future reductions are likely, given stricter emissions standards for on-road vehicles. The heavy-duty off-road sector offers significant fuel-saving potential, as its focus has traditionally been on reliability and performance rather than fuel efficiency. This dissertation examines fuel and CO2e savings opportunities on a heavy-duty off-road material handler, the Pettibone Cary-Lift 204i, from stock configuration to simple modifications to a complete teardown and reconfiguration of the machine with a plug-in series hybrid architecture using electrified hydraulics. The study begins by modeling the baseline machine’s fuel and energy consumption, calibrating with experimental data from custom operating cycles. An energy analysis identifies key areas for fuel savings. Two simple powertrain modifications result in a combined 16.2% fuel savings. Next, a Pugh-style analysis narrows a list of electrified architectures, leading to high-fidelity models that evaluate total lifetime CO2e and costs. Higher electrification levels reduce CO2e emissions but increase costs, and electricity grid emissions significantly impact CO2e for plug-in architectures. A plug-in series hybrid is chosen for the project. In its base control form, 49% fuel and 29% CO2e savings are expected from the plug-in series hybrid compared to the baseline machine. Further savings are pursued through regenerative braking (6.3%) and load-following hydraulic control (17.8%), totaling 24.1% fuel savings, and leading to a total of 61% fuel and 41% CO2e savings compared to the baseline. Battery chemistries and charging strategies are also analyzed for cost and CO2e impacts, finding LFP batteries as superior due to longevity, and overnight level 2 charging usually at a lower cost but resulting in higher emissions than opportunity DC fast-charging (DCFC). DCFC emissions are highly dependent on grid emissions, and DCFC cost is highly dependent on grid demand charges. Finally, artificial intelligence is applied to operating cycle recognition. Neural network accuracy ranges from 81% to 99%, with applications to worksite efficiency and safety improvements.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Siting and sizing of public–private charging stations impacts on household and electric vehicle fleets
To facilitate the provision of electric vehicle charging stations (EVCS) in urban areas, this study investigates the benefits of co-locating fleet-owned chargers with public charging stations to enable construction incentives and cord-sharing cost savings. Shared EVCS can serve charging demand from both user types: private (household) EV owners and those managing fleet vehicles – like shared and fully automated EV (SAEV) fleets. Using POLARIS to simulate all person-travel across the 6-county Austin, Texas region, new EVCS were sited and sized with DC fast-charging (DCFC) plugs to lower operating and construction costs while providing public + private (PP) service across an 81-square-mile core geofence (where 200 SAEVs were active) over 24-hour days. When co-location is permitted, 115 DCFC cords were added to the 23 existing (publicly available) stations to enable SAEVs and household EVs (HHEVs) charging access, within the geofence. Each 250-mile-range SAEV was simulated to travel an average of 330 miles per day, serve over 92 person-trips, and recharge 2.7 times a day (for 2.4 h per session). The new DCFC plugs were primarily added to public EVCS at shopping centers and schools, and in residential settings along freeways. The average plug served 4.8 EVs per day. Most co-located PP EVCS permitted immediate (no-wait) charging, except for 2 stations along freeways that averaged 8 min of wait time to begin charging. In conclusion, the co-location strategy lowered fleet owners’ initial EVCS construction costs by 12 % (thanks to cord-sharing to avoid cord duplication), while reducing SAEV wait times to just 3.1 min (versus 10.7 min if SAEV managers had to build and operate their own EVCS).
EV charging modeling↗
Design, Control, and Protection of a 13.2 kV, 1 MVA Solid State Transformer for Electric Vehicle Extreme Fast Charging Station
In this article, a medium-voltage (MV) ac-dc solid state transformer (SST) for electric vehicle (EV) extreme fast charging (XFC) station is proposed. The SST adopts a cascaded H-bridge (CHB)-based structure where the active front end (AFE) power stages are connected in input-series followed by dual active bridge (DAB) converters connected in an output-parallel configuration providing galvanic isolation through a high-frequency transformer (HFT). The SST is rated for 1 MVA and connects directly to a three-phase 13.2 kV MV ac grid through ac switchgear and outputs 750-V dc. At the dc bus, several dc/dc converters are connected, each of which can charge an EV based on its battery capacity. A novel decentralized control architecture of the SST is adopted in this work which simplifies the MV dc link voltage and module-level power balancing. In addition, the local and central protection designs of the SST are presented which identify and respond to the internal fault of the system. Finally, the experimental validations of the SST hardware prototype are presented up to the rated voltage. Furthermore, this article details the design and implementation of the MV SST addressing the challenges of an isolated MV class power converter for connecting directly to the MV ac grid with unique controller architecture, distributed protection framework, and SST constructional features.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
The ion-ion correlations in organic ionic plastic crystal
Organic ionic plastic crystals (OIPCs) are emerging as promising electrolyte materials for solid-state batteries. However, despite the fast ionic diffusion, OIPCs exhibit relatively low DC conductivity in solid phases caused by strong ion-ion correlations that suppress charge transport. To understand the origin of this suppression, we performed a study of ion dynamics in the OIPC 1-Ethyl-1-methylpyrrolidinium bis (trifluoromethyl sulfonyl) imide [P 12 ][TFSI] utilizing dielectric spectroscopy, light scattering, and Nuclear Magnetic Resonance diffusometry. Comparison of the results obtained in this study with the published earlier results on an OIPC with a completely different structure (Diethyl(methyl)(isobutyl)phosphonium Hexafluorophosphate [P 1,2,2,4 ][PF 6 ]) revealed strong similarities in ion dynamics in both systems. Unlike DC conductivity, which may drop more than ten times between melted and solid phases, diffusion of anions and cations remains high and does not show strong changes at phase transition. The conductivity spectra in the broad frequency range demonstrate unusual shapes in solid phases with an additional step separating fast local ion motions from suppressed long-range charge diffusion controlling DC conductivity. We suggested that in solid phases, anions and cations can jump only between the specific ion sites defined by the crystalline structure. These constraints lead to strong cation-cation and anion-anion correlations strongly suppressing long-range charge transport.
36 MATERIALS SCIENCE↗
Submodule-Level Decentralized Control for Cascaded Quadruple Active Bridge-Based Medium-Voltage Converters
High-power, low-voltage DC (LVDC) loads, such as AI data centers, electric vehicle fast-charging hubs, and hydrogen electrolyzers, are accelerating the deployment of solid-state transformers (SSTs) that directly interface medium-voltage AC (MVAC) to LVDC, streamlining power delivery. This paper proposes a submodule-level decentralized control strategy for an SST comprising a cascaded H-bridge (CHB) active rectifier on the MVAC side and per-module quadruple-active-bridge (QAB) converters on the LVDC side with local controllers. The proposed strategy eliminates the need for high-fidelity, real-time cross-isolation communication by synchronizing all active bridges to a common heartbeat signal and enabling the primary- and secondary-side controllers to generate independent local control signals (phase shifts). The resultant phase shifts naturally govern average and double-line frequency power transfer between active bridges, enabling each side to meet its control objectives using only local measurements. Detailed controller design considerations are presented based on a stability analysis. Comprehensive electromagnetic-transient simulations demonstrate tight DC-link voltage regulation, high-quality grid currents, and robust operation under load transients and grid disturbances, without real-time communication among the submodule controllers. These results indicate that the proposed scheme can significantly enhance the reliability, scalability, and flexibility of cascaded bridge-based medium-voltage converters.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Submodule-Level Decentralized Control for Cascaded Quadruple Active Bridge-Based Medium-Voltage Converters: Preprint
High-power, low-voltage DC (LVDC) loads, such as AI data centers, electric vehicle fast-charging hubs, and hydrogen electrolyzers, are accelerating the deployment of solid-state transformers (SSTs) that directly interface medium-voltage AC (MVAC) to LVDC, streamlining power delivery. This paper proposes a submodule-level decentralized control strategy for an SST comprising a cascaded H-bridge (CHB) active rectifier on the MVAC side and per-module quadruple-active-bridge (QAB) converters on the LVDC side with local controllers. The proposed strategy eliminates the need for high-fidelity, real-time cross-isolation communication by synchronizing all active bridges to a common heartbeat signal and enabling the primary- and secondary-side controllers to generate independent local control signals (phase shifts). The resultant phase shifts naturally govern average and double-line frequency power transfer between active bridges, enabling each side to meet its control objectives using only local measurements. Detailed controller design considerations are presented based on a stability analysis. Comprehensive electromagnetic-transient simulations demonstrate tight DC-link voltage regulation, high-quality grid currents, and robust operation under load transients and grid disturbances, without real-time communication among the submodule controllers. These results indicate that the proposed scheme can significantly enhance the reliability, scalability, and flexibility of cascaded bridge-based medium-voltage converters.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Time Matters: A Survival Analysis of Public Electric Vehicle Charging Infrastructure Utilization
The rapid adoption of plug-in electric vehicles (PEVs) places significant demands on public charging infrastructure, making it critical to understand and optimize charger utilization. This study provides one of the most comprehensive analyses of charging behavior to date by applying a survival analysis to a dataset of nearly 16 million level 2 (L2) and direct current (DC) fast charger sessions across the United States from 2017 to 2022. Using Kaplan-Meier curves and log rank tests, our analysis reveals statistically significant and distinct duration patterns influenced by charger type, time of day, and day of the week. We find that L2 charging sessions exhibit high variability tied to venue type, whereas DC sessions are more uniform, typically lasting 30-45 min. This study introduces the operational efficiency score (OES), a metric for standardizing the performance evaluation of charging stations. Our findings offer actionable insights for optimizing charger deployment, developing dynamic pricing strategies to reduce vehicle dwell time, and improving load management for grid operators, ultimately enhancing the efficiency and availability of public charging infrastructure.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗