ChargeX Prescribed Testing Program at CharIN November 2024 Testival Outcomes & Future Recommendations
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Thurston, Sam↗
Engineering topics
Thurston, Sam
Publications and source records attributed to Thurston, Sam.
EVs@Scale Next-Gen Profiles - Fleet Utilization 2024
As part of the U.S. Department of Energy’s EVs@Scale initiative, the Next-Gen Profiles (NGP) project provides a comprehensive, data-driven analysis of electric vehicle (EV) and electric vehicle supply equipment (EVSE) operations across real-world fleet deployments. This paper presents findings from the NGP’s Fleet Utilization study, which investigates operational behavior and asset usage across seventeen EV fleets and two EVSE fleets, encompassing a wide range of vehicle types and use cases. Data collected from diverse sources—varying in format and temporal resolution—are first reformatted into a unified structure. From this harmonized dataset, a suite of rigorously defined performance metrics is calculated at an hourly cadence, enabling consistent cross-comparison of charging, routing, and other key operational behaviors. Amid rapidly increasing EV adoption and growing demands for energy-efficient fleet operations, the analysis reveals clear utilization trends—including diurnal and weekly activity cycles, differences in short versus long charging session dependencies, and route-specific energy usage patterns. These findings highlight the need for tailored infrastructure strategies and the deployment of advanced energy management systems, such as Distributed Energy Resource Management Systems (DERMS) and Site Energy Management Systems (SEMS), which can optimize charging schedules and mitigate peak loads. By leveraging anonymized, harmonized datasets and standardized metrics, this study offers critical insights into fleet behavior and performance, providing a foundation to improve operational efficiency, reduce costs, and enable the scalable deployment of electrified transportation.
Wells, Landon↗
EVs@Scale Next-Gen Profiles - EV Profile Capture 2024
As part of the U.S. DOE EVs@Scale consortium Next-Gen Profiles (NGP) project, the profile capture and analysis of production electric vehicles undergoing high power charging (HPC) is conducted over a wide range of conditions to explore variance and performance. Charge session parameters are collected from both the electric vehicle (EV) and electric vehicle supply equipment (EVSE) at a rate of 10Hz and entered into a time-series database for analysis. These charge profiles are captured under nominal and off-nominal conditions, exploring the impact of battery state of charge (SOC), battery temperature, vehicle condition, smart charge management (SCM), and EVSE limitations. Nominal conditions are defined to be ideal conditions that should transfer the maximum allowable energy in the minimum possible amount of time. Nominal condition profiles are compared across EVs to characterize state-of-the-art EV charging performance against one another. Off-nominal condition profiles are compared against its nominal condition profile counterpart to highlight the variance across less desirable starting conditions within a single EV. This EV Profile Capture 2024 report stands as an update from the EV Profile Capture 2023 report to include the additional EV & EVSE assets tested and analyzed in 2024. The major updates within this report include the addition of three next-generation electric vehicles, added test cases, and further analysis. This expansion of analysis includes power profiles, power distribution, quantifying SOC, energy and range performance, EVSE limitation impacts, boost converter performance, etc. Additionally, NGP time-series data has been used as input towards three national laboratory-led grid modelling efforts: ANL’s IEEE-37 HIL model, INL’s Caldera model, and NREL’s EVI-X model. A summary of these platforms and how NGP has worked to improve their effectiveness has also been added to this years’ report.
Thurston, Sam↗
ChargeX Prescribed Testing Program at CharIN June 2024 Testival: Outcomes & Future Recommendations
In June 2024, the ChargeX Consortium developed an optional prescribed testing program for electric vehicle (EV) and electric vehicle supply equipment (EVSE) manufacturers that attended the CharIN Testival as testers. There were two driving purposes of this program; to introduce a new hybrid approach to testing events with both ad-hoc and prescribed testing offered, and to demonstrate the test cases and structure effectiveness of the EV-EVSE Interoperability Test Plan (EEITP) document developed within the ChargeX Testing Task Force. This program contained eight test scenarios to be performed during the final 30-minutes of a 90-minute testing slot with details like purpose, setup, pass criteria, etc. included within a written test plan document. A $2,000 rebate was offered to those who participated, and a ChargeX moderation force was present to collect EV and EVSE meta data, testing meta data, and testing results.
33 ADVANCED PROPULSION SYSTEMS↗
Slide Decks for EV@S Stakeholder Meeting at INL September 2024
These slides were used at the Electric Vehicles at Scale National Lab Consortium, Stakeholder Meeting hosted at INL in September 2024. The slides are now requested to be made available publicly for reference. All slides review projects that are already in the public domain and their information is intended for public release. They are not from sensitive topics or areas with any restrictions. A few projects are overviewed in detail and some slides were just an aid to the breakout sessions that were conducted with stakeholders and lab staff.
25 ENERGY STORAGE↗
2024 Electric Vehicles at Scale Semiannual Stakeholder Meeting
The U.S. Department of Energy (DOE) Electric Vehicles at Scale Lab Consortium (EVs@Scale Lab Consortium) is accelerating research to support the establishment of a secure and scalable national network of charging infrastructure. This network will be critical to support tens of millions of light-, medium-, and heavy-duty EVs on American roads by 2030. The EVs@Scale Lab Consortium brings together national laboratories and key stakeholders to conduct infrastructure research and development (R&D) that advances innovations in, and sets unified standards for, high-power and wireless charging. The effort will also develop technologies to integrate vehicle charging with the power grid, and develop cybersecurity measures to protect drivers, vehicles, equipment, and the grid. The first hybrid EVs@Scale Lab Consortium Semiannual Stakeholder Meeting was held at ANL on September 27-28, 2023, to identify research, development, and deployment needs to accelerate technology development for electric vehicles at scale and explore opportunities for collaboration across government, academia, and industry.
advanced charging and grid interface technologies↗
EVs@Scale Next-Gen Profiles - EV Profile Capture 2023
As part of the U.S. DOE EVs@Scale consortium Next-Gen Profiles (NGP) project, the profile capture of production electric vehicles undergoing high power charging (HPC) is conducted over a wide range of conditions to explore variance and performance. Charge session parameters are collected from both the electric vehicle (EV) and electric vehicle supply equipment (EVSE) at a rate of 10Hz and entered into a time-series database for analysis. These charge profiles are captured under nominal and off-nominal conditions, exploring the impact of battery state of charge (SOC), battery temperature, vehicle condition, smart charge management (SCM), and EVSE limitations. Nominal conditions are defined to be ideal conditions that should transfer the maximum allowable energy in the minimum possible amount of time. Nominal condition profiles are compared across EVs to characterize state-of-the-art EV charging performance against one another. Off-nominal condition profiles are compared against its nominal condition profile counterpart to highlight the variance across less desirable starting conditions within a single EV. Under nominal conditions, most EVs can achieve the original equipment manufacturer (OEM) rated peak-power and charge times. Peak power across EVs has variance due to the vehicle design, battery topology, charging strategy, etc. These 10-100% nominal preconditioned charge profiles across 13 EVs (11 light-duty (LD), 2 heavy-duty (HD)) were used for analysis in power curve analysis, power distribution, SOC and range comparison, thermal impacts of current draw, battery pack size and energy charged, and ramp rates. Power curve analysis show the uniqueness in power vs time curves across all EVs, breaking down the features of a typical profile and where variation is typically seen. Power distribution results showed that over 50% of charge time is spent below 50kW and only 12.1% is spent above 200kW. SOC and range performance yielded different top performing EVs when exploring goals of performance from SOC and range gained after 10-min (EV2) and 20-min (EV8), and time-to-achieve 80% SOC (EV8) and 200 miles of range (EV1). Current draw from 400-volt EVs had a higher thermal impact to cable/connector temperatures when compared to 800-volt EVs, due to a higher current requirement to achieve similar power levels. There was high variance in C rating, a useful metric when comparing the relationship between peak/average charge session power and relative battery pack size, across EVs under test. Ramp rates during initial power transfer were examined, fastest and slowest speeds ranging from 192.5kW/second to 2.6kW/second respectively. A similar analysis of ramp rates was also conducted for OCPP curtailment testing, where EVs underwent a 2-minute 65A curtailment request before returning to full-power charge. Under off-nominal conditions, most EVs experienced variation from the nominal condition profiles. EVs that underwent the full set of NGP defined testing conditions were compared, analysis of which was categorized by 800-volt and 400-volt EVs. It should be noted that the 800-volt EVs had significantly higher peak power ratings than the 400-volt EVs, and thus were more prone to variance. Initial state of charge, battery temperature, and vehicle condition had a considerable impact on peak power levels and charge time for the 800-volt vehicles under test. EVSE limited tests lowered achievable power down to 200kW, greatly impacted 800-volt charging power, and had little to no effect on 400-volt charging power. Adapter testing was performed on a single 400-volt EV, where power and current limitations were found but overall charge time was not significantly impacted. Adapter and boost converter testing was performed on a single 800-volt EV, where both charge power and charge time were greatly impacted. Charge profiles are unique, and comparing such requires analysis that examines starting conditions, vehicle and battery topologies,
Charging↗
EVs@Scale Next-Gen Profiles - Fleet Utilization 2023
As U.S. fleet operators begin transitioning to electric vehicles (EVs), critical questions arise regarding how to manage this shift without disrupting fleet operations or placing undue stress on the electric grid. A major challenge for fleets is maintaining effective operational schedules while accommodating charging requirements, particularly with high-power charging (HPC) infrastructure, which presents grid stability concerns for utilities. Proposed solutions such as charging substations, megawatt charging systems (MCS), and smart charge management systems (SCMS) offer potential pathways forward, but their effectiveness depends on alignment with real-world fleet behavior and operational constraints. This report investigates the charging and utilization behavior of EV and EVSE fleets actively employing HPC technologies by conducting detailed case study analyses based on telematics data. A suite of predefined metrics—covering charging, routing, and other operational behaviors—is developed to evaluate the impact of fleet activities on grid infrastructure and identify opportunities for optimization. Results highlight variations in charging behavior across fleets, such as weekday versus weekend usage, diurnal charging trends, and the role of operational predictability in enabling SCMS effectiveness. While SCMS can help lower costs and improve energy efficiency for fleets with stable schedules, they may be insufficient for fleets with highly variable or long-haul operations, which may require more robust solutions like MCS. Visualization of aggregated hourly energy metrics reveals that while fleet behaviors are diverse, there are common temporal patterns that could inform infrastructure planning and energy management. These insights emphasize the need for fleet-specific charging strategies that minimize grid impact while supporting reliable fleet operations. Additionally, the report underscores the broader economic stakes of electrification, particularly in high-value markets such as freight, where misaligned transitions could stall EV adoption. By examining current EV and EVSE fleet deployments using predetermined standardized metrics, this study offers a foundation for developing technologies and operational frameworks that support scalable, grid-compatible electrification across a variety of fleet types while establishing a baseline understanding of operational behaviors. In doing so, we aim to ensure that future charging solutions reflect actual fleet needs and grid constraints—an essential step toward maintaining operational continuity and achieving a successful transition to electric fleet operations.
Charging↗
EVs@Scale Lab Consortium Semi-Annual Stakeholder Meeting
The U.S. Department of Energy (DOE) Electric Vehicles at Scale Lab Consortium (EVs@Scale Lab Consortium) is accelerating research to support the establishment of a secure and scalable national network of charging infrastructure. This network will be critical to support tens of millions of light-, medium-, and heavy-duty EVs on American roads by 2030. The EVs@Scale Lab Consortium brings together national laboratories and key stakeholders to conduct infrastructure research and development (R&D) that advances innovations in, and sets unified standards for, high-power and wireless charging. The effort will also develop technologies to integrate vehicle charging with the power grid, and develop cybersecurity measures to protect drivers, vehicles, equipment, and the grid. The first hybrid EVs@Scale Lab Consortium Semiannual Stakeholder Meeting was held at ANL on September 27-28, 2023, to identify research, development, and deployment needs to accelerate technology development for electric vehicles at scale and explore opportunities for collaboration across government, academia, and industry.
advanced charging and grid interface technologies↗
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↗