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DOE OSTI2023

Electric Vehicles at Scale (EVs@Scale) Laboratory Consortium Deep-Dive Technical Meetings: High Power Charging (HPC) Summary Report

Electric vehicle (EV) adoption will change the composition of EV charging load to higher-power charging as more medium- (MD) and heavy-duty (HD) applications are electrified, and as all vocations, including light-duty (LD) vehicles, are capable of faster charging. These shifts provide the opportunity for high-power charging (HPC) and facility equipment to evolve and improve efficiency, cost, and space. High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project designs and develops a high-power, interoperable charging experimental platform to research, develop, and demonstrate the integration approaches and technology solutions. The project addresses (1) interconnection and management of a grid-tied inverter; (2) development of a DC distribution system that is responsible for system energy management, interoperability, and DC protection; (3) modular DC/DC conversion for vehicle charging; (4) EV charging interface and DC/DC integration; and (5) smart charge control and vehicle-to-edge (vehicle-to-building [V2B], vehicle-to-everything [V2X]) capability. This summary presentation is the first technical progress output of the project. It provides insight for the first deep-dive technical meeting outputs in terms of research presentations and also includes summary of the discussions occurred in the follow-up breakout sessions. The summary presentation covers three technical areas: (1) HPC: State of the art power architectures and the design of the power electronics, (2) Modeling, energy management, and power control in the HPC station, and (3) Next Generation Profiles for high power charging characterization.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Electric Vehicles at Scale (EVs@Scale) Laboratory Consortium Deep-Dive Technical Meetings: High Power Charging (HPC) Summary Report

Electric vehicle (EV) adoption will change the composition of EV charging load to higher-power charging as more medium- (MD) and heavy-duty (HD) applications are electrified, and as all vocations, including light-duty (LD) vehicles, are capable of faster charging. These shifts provide the opportunity for high-power charging (HPC) and facility equipment to evolve and improve efficiency, cost, and space. High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project designs and develops a high-power, interoperable charging experimental platform to research, develop, and demonstrate the integration approaches and technology solutions. The project addresses (1) interconnection and management of a grid-tied inverter; (2) development of a DC distribution system that is responsible for system energy management, interoperability, and DC protection; (3) modular DC/DC conversion for vehicle charging; (4) EV charging interface and DC/DC integration; and (5) smart charge control and vehicle-to-edge (vehicle-to-building [V2B], vehicle-to-everything [V2X]) capability. This summary presentation is the first technical progress output of the project. It provides insight for the first deep-dive technical meeting outputs in terms of research presentations and also includes summary of the discussions occurred in the follow-up breakout sessions. The summary presentation covers three technical areas: (1) HPC: State of the art power architectures and the design of the power electronics, (2) Modeling, energy management, and power control in the HPC station, and (3) Codes and standards work that are in line with the previous two topic areas.

ADVANCED PROPULSION SYSTEMS,POWER TRANSMISSION AND↗

DOE OSTI2024

Nov. 2024 EVs@Scale High-Power Charging Deep Dive Technical Meeting

EVs@Scale Lab Consortium is addressing challenges, developing solutions, and enabling technologies for transportation electrification ecosystem. The consortium has five research pillars one of which focuses on high power charging (HPC). HPC pillar brings together hardware and software expertise, capabilities, and facilities related to high power EV charging, charge management, and grid integration. Deep-dive technical meetings are organized twice a year and provides an opportunity for more industry engagement and technical feedback for the national labs throughout the project lifecycle. High-Power Charging pillar has two active projects: (i) Next-Gen Profiles (NGP) and (ii) High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP). This presentation summarizes the progress made in both projects during the past six months focusing on specific topics. There will be two deep-dive technical meetings twice a year. Every deep-dive meeting will focus on different aspects of the project progress.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗

DOE OSTI2024

EVs@Scale High-Power Charging (HPC) Pillar Deep-Dive Technical Meeting

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 OSTI2024

EVs@Scale Lab Consortium High-Power Charging Pillar Deep-Dive Technical Meeting

Managed under the the U.S. Department of Energy (DOE)-funded EVs@Scale Consortium, the High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project aims to create an experimental platform for integration and control approaches in a direct current (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 a DC-coupled charging hub ("DC hub" for short). This report explains the design, development, and implementation process of an experimental platform for the DC hub. DC distribution holds significant potential for enhancing the operation of an HPC station architecture. However, there are challenges in establishing a DC hub, including interoperability, commoditization, distributed energy resource integration, stability, DC protection, and a 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. The developed proof-of-concept charging platform and open-source SEMS allow the development and testing of various controllers and chargers from different vendors. The DC hub platform integrated EVs, an ESS, a PV system, and building load to demonstrate the flexibility of the platform. The open-source SEMS controlled the devices within the hub using a rule-based implementation, realizing available standards.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Controller Hardware-in-the-Loop Modeling and Operation of a High-Power DC Charging Hub

High-power charging (HPC) concept will be a critical enabler for the wide-scale adoption and integration of electric vehicles (EVs). HPC hubs will have a significant impact on achieving this goal, particularly when considering the charging requirements of next-generation medium and heavy-duty vehicles (MD/HD) used in various vocational scenarios. This emphasizes the significance of evaluating and confirming the technical planning and multi-level operation of HPC hubs through modeling, protocol implementation, and simulation before hardware demonstration. The focus of this study is to develop the architecture, modeling, communication, and real-time controller hardware-in-the-loop (C-HIL) simulation of HPC hubs using the DC distribution system approach. Specifically, this work demonstrates the practical implementation of a custom Smart Energy Management System (SEMS) for a real-time C-HIL HPC hub simulation using the Open Charge Point Protocol (OCPP) for communication. OCPP is implemented on the Node-Red framework and the custom controller is executed in Python. We developed a rule-based controller to demonstrate the proposed approach.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Station Impact Analysis 2025

As part of the U.S. DOE EVs@Scale consortium, the NextGen Profiles (NGP) project presents analysis and results from the study of High Power Charging Electric Vehicles and Battery Charging Infrastructure. High Power Charging equipment is capable of recharging electric vehicle traction batteries at power levels of 200KW and above. The intent of the project is to further understand the most recent technological capabilities of the electric mobility industry related to charging performance. The project aims to develop EV, EVSE, and Fleet characterization testing practices and comprehensive analysis with inputs from key industry stakeholders. The results published in this NextGen Profiles project report provide data and insight for use by numerous entities including modeling and simulation organizations, policy makers, fleet planners, industry stakeholders and the general public involved with the development, deployment and operation of electrified transportation technologies. The factors influencing Electric Vehicle (EV) Direct Current Fast Charging (DCFC), including EV battery specifications, temperature effects on lithium-ion battery and power electronics performance, lithium-ion battery SOC bounding and charging station design considerations are specifically investigated to analyze their impacts on charging station operation and recommendations are made to minimize charge station dwell time, reduce charging costs and mitigate electric grid and charge station congestion. Additional high-power charging results are anticipated in future publications in support of the U.S. DOE EVs@Scale consortium NextGen Profiles project.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

EVs@Scale NextGen Profiles: High Level Analysis and Procedures Report

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Electric Vehicle Infrastructure Consequence Assessment

With consumers’ growing interest in electric vehicles, extreme fast charging stations are poised to provide high-power charging to rapidly recharge light-duty passenger vehicles. High-power charging requires high-level communication between vehicle and charger to govern the charging process. The coupling of power and communication increases the potential scale of cyberattacks. Using a full Western Electricity Coordinating Council planning model, load manipulation from high-power charging infrastructure is investigated. Two cases of load manipulation are studied: (i) a discrete, widespread system event and (ii) loads modulated near the Western Interconnect’s resonant frequency. In (i) some generation trips and in (ii) oscillations are observed on the California Oregon Intertie. Neither scenario results in significant adverse effects to the grid.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Consequence-Driven Cybersecurity for High-Power Electric Vehicle Charging Infrastructure

Cybersecurity of high-power charging infrastructure for electric vehicles (EVs) is critical to the safety, reliability, and consumer confidence in this publicly accessible technology. Cybersecurity vulnerabilities in high-power EV charging infrastructure may also present risks to broader transportation and energy-infrastructure systems. Here, this paper details a methodology used to analyze and prioritize high-consequence events that could result from cybersecurity sabotage to high-power charging infrastructure. The highest prioritized events are evaluated under laboratory conditions for the severity of impact and the complexity of cybersecurity manipulation. Mitigation solutions and strategies are presented to secure the vulnerabilities that potentially lead to high-consequence events. These mitigations can be immediately implemented by industry or executed during the design stage.

25 ENERGY STORAGE↗

DOE OSTI2024

Overview of High-Power Wireless Charging Systems and Analysis of Polyphase Wireless Charging System Phase Winding and Resonant Tuning Network Connection Configurations

In spite of the high energy efficiency and environmental benefits of electric vehicles (EVs), adoption rates are increasing at a relatively slow pace, primarily because of EVs’ limited range and long charging durations. To reduce EV charging times to be comparable to refueling times of conventional vehicles, extreme fast charging systems are required. Such charging systems would reduce drivers’ range anxiety and enable long-distance interstate travel with EVs. Here, this substantial target in charging rates with 15–20 minutes of recharging times, requires research and development from grid to batteries with advanced charging systems. Wireless power transfer systems for EV charging applications are flexible, convenient, and highly efficient, and they allow automated charging. This paper reviews the power electronics and winding and resonant tuning network configurations for polyphase wireless power transfer systems for high-power wireless charging applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Thermal Design and Optimization of High- Power Wireless Charging System

In this paper, the thermal design and optimization of a high-power wireless charging system (WCS) is proposed. An integrated electromagnetic and thermal co-optimization is essential to design a high power-density WCS pad. This study presents the thermal analysis and the potential optimization scopes for a polyphase WCS pad. The coil and core causes most of the power losses of a WCS pad and causes thermal hotspot in the pad. In this paper, the thermally conductive epoxy is introduced to balance the effective volumetric loss density in the pad and mitigate the thermal hotspots in the coil and core. The proposed design is simulated through finite element analysis (FEA) and tested experimentally for a 50 kW three-phase WCS. Simulation and experimental results show that the conventional design has localized hotspots in the coil and core. The proposed thermal design mitigates the thermal hotspots without increasing the coil or core volume.

Mohammad, Mostak↗

DOE OSTI2025

Hybrid Energy Management with Real-Time Control of a High-Power EV Charging Site

Decarbonization of transportation systems is driving higher capacity energy storage and faster charging power requirements in electric vehicles (EVs). Given the potential advantages - such as increased efficiency, reduced inverter capacity, and less total cable mass - there is a demand in the industry for more DC distribution for high-power charging (HPC) hubs. However, the cost-effective, adaptive, and robust operation of the DC-coupled HPC hub necessitates a robust site energy management system (SEMS). Validating SEMS operation using a digital twin of an HPC hub in a real-time simulator (RTS) platform is crucial before field deployment. In this study, we propose a hybrid energy management site controller designed to achieve high-level, long-term operational objectives while managing low-level power sharing control between hub assets. We develop a centralized model predictive controller (MPC) to optimize hub operating points and use these points to update the droop parameters of the site energy storage system (ESS). This approach ensures the hub follows an optimal operating point while maintaining the flexibility to respond to load surges. We tested and verified our proposed approach both offline and on a Controller Hardware-in-the-loop (C-HIL) simulation platform integrated with a SEMS framework, demonstrating real-time site operation and validating a cost-effective and robust site controller.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Development of a DC Distribution Testbed for High-Power EV Charging

This paper explores the design and implementation of a power hardware-in-the-loop (P-HIL) setup for DC distribution infrastructure integrated with high-power charging (HPC) of electric vehicles (EVs), DC loads, and sources. The utilization of DC distribution holds significant potential for enhancing the operation of a HPC station architecture. However, there are challenges establishing a DC charging 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 to evaluate different use cases at rated power and voltage levels. The developed P-HIL setup features a dedicated DC charging hub, DC-coupled chargers, DC loads/sources, DC protection, and a communication architecture. The integrated P-HIL system provides a versatile testing environment to address technology and interoperability gaps and implements a smart energy management system (SEMS). This platform enables comprehensive and robust testing of COTS devices, charger prototypes, SEMS controllers and protection schemes, which together will accelerate transition to EVs at scale. The setup is tested for various use-cases at full-scale, integrating 950 V DC bus voltage, 660 kW grid-tied inverter, 150 kW COTS charger, and 100 kW energy storage system within an open-source SEMS platform.

ADVANCED PROPULSION SYSTEMS,POWER TRANSMISSION AND↗

DOE OSTI2026

Optimal Litz Wire Design for High-Power Wireless Charging System

In this study, an optimized Litz wire and polyphase coil winding design is proposed for high-power wireless charging systems operating at 85 kHz frequency. Litz wire in a wireless charging system contributes to more than half of the losses of the system, making it a critical design component. Here, the Litz wire is optimized through Finite Element Analysis (FEA) considering electrical and mechanical design aspects and the design was validated through experimental tests on different Litz wires with various strand-diameters, twisting ratio, and number of strands. The proposed optimal Litz wire maximizes the system efficiency considering the tradeoff between coil resistance and mutual inductance. The optimal Litz wire shows that Litz wire constructed with the 63µm strands significantly outperform the traditionally used Litz wire with 100µm strand diameter. Additionally, the coil with optimal Litz wire design shows 60% reduction in the copper volume for the same loss, and at the same time increase the coil-to-coil efficiency by more than 2% by increasing the mutual inductance and reducing coil current. The optimized Litz wire was implemented in a 22-kW wireless charging system achieving 94.7% efficiency.

Aydin, Emrullah [ORNL]↗

DOE OSTI2022

Universal Battery Supercharger

During the course of the UBS project a dc-fast charger was developed to be used in off board high power charging stations. High efficiency is targeted to reduce the charging price for the consumer while reducing the charge time. In the meantime, the size of the converter is minimized so that it could be used in small spaces and potentially urban areas. The topology is modular, and the power level can be expanded for charging higher power vehicles like trucks and buses. During the course of this research several key technologies was developed in LESES that improve the performance of the power electronics system used in EV charger. Integrated magnetics was developed for DMCR to improve the power density as well as efficiency of the magnetic components which is one of the main bottlenecks of EV development. Triangular mode EV current conduction mode is using to perform soft switching (increase efficiency) without adding any new components to the existing topology. Passive and active damping are developed to suppress the interaction between grid and converter, stabilizing the control system. Further numerous other technical problems have been solved to pave the way for even higher performance converters in the future.

25 ENERGY STORAGE↗

DOE OSTI2022

Grid impact analysis using controller-hardware-in-the-loop for high-power vehicle charging stations

A controller-hardware-in-the-loop (CHIL) architecture for the evaluation of grid impacts arising from high-power vehicle charging stations is presented in this paper. Unlike simulation-based studies, the proposed method can be used to capture the interactions of the grid and the charging load along with charger controllers in real time. The proposed method can be used to evaluate the impact of charging load on the grid in terms of voltage variations and line congestion. The proposed CHIL platform allows for de-risking the vehicle charging station deployment by simulating the complex interactions among all the components of a vehicle charging station - i.e., the grid, vehicle, and charger controller - in a realistic manner before using the charging station in a grid. Further, the proposed CHIL approach can be used to evaluate the voltage regulation causalities of the vehicle charging station. Experimental results are presented in the paper to illustrate the applicability of the proposed method in a laboratory environment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗