Results for “vehicle controller” — Page 42

DOE OSTI2024

Investigation of Ammonia Carrier Materials for Next Generation Ammonia Dosing System - CRADA 334 (Abstract)

Lean-burn gasoline and diesel engines can offer substantially higher fuel efficiency, good driving performance, and reduced carbon dioxide emission compared to stoichiometric gasoline engines. Various catalyst technologies have been developed to remove the pollutants from these engines. For example, a three-way catalyst (TWC) is used to remove hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx) from gasoline engines during the stoichiometric conditions. During the lean-burn conditions, a TWC or a diesel oxidation catalyst (DOC) is used to control HC and CO emissions. NOx is removed by either lean NOx trap catalyst (LNT) that can store NOx under lean conditions and reduce NOx under rich conditions, or selective catalytic reduction catalyst (SCR) that can selectively remove NOx with a reducing agent. Among the NOx reduction catalyst technologies, SCR offers a number of advantages, including excellent NOx reduction efficiency over a wide range of temperatures and overall lower system cost. In fact, the SCR technology using ammonia (NH3) as reductant has been proven effective and used commercially for the removal of NOx emissions from stationary sources since the 1970s. Currently, SCR is being used to meet the NOx emission standards for diesel engines in Europe and North America, and also being considered for meeting the future NOx emission standards for lean-burn gasoline engines. Because of the challenges associated with storage, handling and transportation of ammonia on a vehicle, aqueous urea solution (e.g., Diesel Exhaust Fluid, AdBlue) has been developed as ammonia storage compound for mobile applications. When the aqueous urea solution is sprayed into exhaust gas stream, urea is decomposed to release ammonia, which then reduces NOx over the downstream SCR catalyst. Although aqueous urea solution technology has enabled automakers and engine manufacturers to meet the current NOx emission standards, this process of releasing ammonia requires a hot exhaust gas and sufficient mixing, creating challenges for low temperature NOx emission control and aftertreatment system packaging. For these reasons, alternative technologies have been developed as ammonia sources (e.g., solid urea, ammonium carbamate, metal ammine chloride) during the past few years. These technologies promise more convenient handling and distribution of ammonia sources, and help maximize the low-temperature performance of SCR catalysts and reduce the overall system volume and weight. However, none of these alternative technologies can be successfully implemented without the industry consensus. Therefore, the USCAR SCR work group, which is comprised of representatives from GM, Ford, and Chrysler, has decided to investigate the potential alternative ammonia carriers, define common standard vehicle interfaces, and address personal and environmental safety concerns with part suppliers and chemical companies. Under this CRADA Project, USCAR and Battelle will investigate alternative ammonia carrier materials that are currently under development. Based on the data and information derived under the CRADA project, the USCAR SCR work group plans to build the consensus and make recommendations for the industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Investigation of Ammonia Carrier Materials for Next Generation Ammonia Dosing System - CRADA 334 (Abstract)

Lean-burn gasoline and diesel engines can offer substantially higher fuel efficiency, good driving performance, and reduced carbon dioxide emission compared to stoichiometric gasoline engines. Various catalyst technologies have been developed to remove the pollutants from these engines. For example, a three-way catalyst (TWC) is used to remove hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx) from gasoline engines during the stoichiometric conditions. During the lean-burn conditions, a TWC or a diesel oxidation catalyst (DOC) is used to control HC and CO emissions. NOx is removed by either lean NOx trap catalyst (LNT) that can store NOx under lean conditions and reduce NOx under rich conditions, or selective catalytic reduction catalyst (SCR) that can selectively remove NOx with a reducing agent. Among the NOx reduction catalyst technologies, SCR offers a number of advantages, including excellent NOx reduction efficiency over a wide range of temperatures and overall lower system cost. In fact, the SCR technology using ammonia (NH3) as reductant has been proven effective and used commercially for the removal of NOx emissions from stationary sources since the 1970s. Currently, SCR is being used to meet the NOx emission standards for diesel engines in Europe and North America, and also being considered for meeting the future NOx emission standards for lean-burn gasoline engines. Because of the challenges associated with storage, handling and transportation of ammonia on a vehicle, aqueous urea solution (e.g., Diesel Exhaust Fluid, AdBlue) has been developed as ammonia storage compound for mobile applications. When the aqueous urea solution is sprayed into exhaust gas stream, urea is decomposed to release ammonia, which then reduces NOx over the downstream SCR catalyst. Although aqueous urea solution technology has enabled automakers and engine manufacturers to meet the current NOx emission standards, this process of releasing ammonia requires a hot exhaust gas and sufficient mixing, creating challenges for low temperature NOx emission control and aftertreatment system packaging. For these reasons, alternative technologies have been developed as ammonia sources (e.g., solid urea, ammonium carbamate, metal ammine chloride) during the past few years. These technologies promise more convenient handling and distribution of ammonia sources, and help maximize the low-temperature performance of SCR catalysts and reduce the overall system volume and weight. However, none of these alternative technologies can be successfully implemented without the industry consensus. Therefore, the USCAR SCR work group, which is comprised of representatives from GM, Ford, and Chrysler, has decided to investigate the potential alternative ammonia carriers, define common standard vehicle interfaces, and address personal and environmental safety concerns with part suppliers and chemical companies. Under this CRADA Project, USCAR and Battelle will investigate alternative ammonia carrier materials that are currently under development. Based on the data and information derived under the CRADA project, the USCAR SCR work group plans to build the consensus and make recommendations for the industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Enhanced Lighting Signals for Safety and Efficiency - Experiments With Addressable LEDs

For enhanced roadway safety, clear and immediate visual cues are essential for preventing accidents between drivers and pedestrians. At intersections, however, the line of sight to other roadway users may be obstructed by vehicles and infrastructure. Additionally, adverse conditions, including low visibility, poor weather, or inadequate lighting can increase the potential for collisions. Distracted drivers and pedestrians can further exacerbate the risk of accidents, particularly when using a smartphone, rather than focusing on roadway surroundings. These issues demonstrate the need for infrastructure upgrades that enhance visibility and awareness at crosswalks. A potential solution is through enhanced lighting signals integrated into the roadway infrastructure. One such example is the use of addressable LEDs, individually controllable lights that can change color and brightness instantaneously through programmable microcontrollers. They can be installed and integrated into crosswalks to maintain visibility in conditions where pedestrians may be difficult to see, while also offering peripheral cues to pedestrians who may be distracted by their phones or other objects rather than the road. Such a system (as one example) that is integrated into a traffic intersection digital twin that tracks all roadway users accurately, has the potential to enhance visibility of vulnerable road users, and thus enhance safety. This paper examines the potential implementation and feasibility of this technology, as well as the safety benefits it could provide. Laboratory experiments with addressable LEDs reveal the capabilities and challenges of this technology for roadway infrastructure safety. These findings could pave the way for more integrated lighting in infrastructure for vehicles and pedestrians at intersections, merge and diverge locations, and other areas where complex interactions present safety hazards. Such lighting solutions, enabled by modern computation and communications, could enhance safety and efficiency in our transportation system and improve overall mobility.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Enhanced Lighting Signals for Safety and Efficiency - Experiments with Addressable LEDs

For enhanced roadway safety, clear and immediate visual cues are essential for preventing accidents between drivers and pedestrians. At intersections, however, the line of sight to other roadway users may be obstructed by vehicles and infrastructure. Additionally, adverse conditions, including low visibility, poor weather, or inadequate lighting can increase the potential for collisions. Distracted drivers and pedestrians can further exacerbate the risk of accidents, particularly when using a smartphone, rather than focusing on roadway surroundings. These issues demonstrate the need for infrastructure upgrades that enhance visibility and awareness at crosswalks. A potential solution is through enhanced lighting signals integrated into the roadway infrastructure. One such example is the use of addressable LEDs, individually controllable lights that can change color and brightness instantaneously through programmable microcontrollers. They can be installed and integrated into crosswalks to maintain visibility in conditions where pedestrians may be difficult to see, while also offering peripheral cues to pedestrians who may be distracted by their phones or other objects rather than the road. Such a system (as one example) that is integrated into a traffic intersection digital twin that tracks all roadway users accurately, has the potential to enhance visibility of vulnerable road users, and thus enhance safety. This paper examines the potential implementation and feasibility of this technology, as well as the safety benefits it could provide. Laboratory experiments with addressable LEDs reveal the capabilities and challenges of this technology for roadway infrastructure safety. These findings could pave the way for more integrated lighting in infrastructure for vehicles and pedestrians at intersections, merge and diverge locations, and other areas where complex interactions present safety hazards. Such lighting solutions, enabled by modern computation and communications, could enhance safety and efficiency in our transportation system and improve overall mobility.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Impact of Transportation Electrification on the System's Dynamic Frequency Response: Preprint

Transportation electrification is an integral component of the energy decarbonization transition. This paper investigates the impact of distributed energy resources (DERs), including distributed photovoltaics (DPV) and electric vehicles (EVs), in the primary frequency response of the power grid. Increasing DER adoption poses challenges to maintaining grid frequency stability. However, DERs' ability to provide fast frequency regulation services-primary frequency response (PFR) and secondary frequency response (SFR)-can be exploited to recover the frequency after an N-1 contingency event in the system. This paper also investigates the importance of a droop control strategy through dynamic models of DPV and EV to provide the primary frequency regulation services following the contingency event. A dynamic EV model, based on the PVDl model Western Electricity Coordinating Council (WECC) introduced, has been used for the simulation. Further, DERs' primary frequency response is studied for five different cases of DER penetration levels after the system is exposed to the generator trip. Additionally, different frequency regulation capacities of EVs are analyzed. The studies show that an increment in DERs capacity providing effective PFR can improve the system frequency nadir and stabilize the frequency faster after the generation trip contingency.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Active Reconditioning of Retired Lithium-ion Battery Packs from Electric Vehicles for Second Life Applications

Utilizing the remaining capacity in retired lithium-ion (Li-ion) batteries from electric vehicles (EVs) for second-life applications has shown economic and environmental benefits. However, achieving homogeneity among the capacities of cells before their second life is critical to exploit the benefits. This article proposes a new active reconditioning approach with the potential to make short-term reconditioning of batteries before second life feasible. A control objective map determines each cell's state-of-charge (SOC) operating window based on its capacity relative to other cells. The SOC reference translates into distinct differential currents through the cells, wherein the higher-capacity cells undergo more frequent and deep charge and discharge cycles than their lower-capacity counterparts. The proposed solution achieves capacity homogeneity within the battery pack with low reconditioning time and minimal fade in the overall pack capacity. The feasibility of the reconditioning approach under varying load and environmental conditions is assessed through simulations, encompassing factors such as the number of cycles per day, depth-of-discharge, battery pack temperature, and cell resting time at different SOCs. Furthermore, the simulation model employs a battery pack with sixteen series-connected 75 Ah Kokam lithium nickel manganese cobalt oxide (NMC) cells with a 3.6% initial capacity imbalance. A reconditioning time of 1.3 months is achieved with a final capacity imbalance of 0.1% and an overall capacity fade of 0.005%, thereby confirming the viability of the reconditioning process. Moreover, experimental validation using eight retired battery cells from a Nissan Leaf demonstrates a substantial decrease in the capacity imbalance of cells from 9.4% to 2.15% within 78 days, effectively affirming the efficacy of the proposed reconditioning scheme.

25 ENERGY STORAGE↗

DOE OSTI2021

A probabilistic graphical model foundation for enabling predictive digital twins at scale

A unifying mathematical formulation is needed to move from one-off digital twins built through custom implementations to robust digital twin implementations at scale. This work proposes a probabilistic graphical model as a formal mathematical representation of a digital twin and its associated physical asset. We create an abstraction of the asset–twin system as a set of coupled dynamical systems, evolving over time through their respective state spaces and interacting via observed data and control inputs. The formal definition of this coupled system as a probabilistic graphical model enables us to draw upon well-established theory and methods from Bayesian statistics, dynamical systems and control theory. The declarative and general nature of the proposed digital twin model make it rigorous yet flexible, enabling its application at scale in a diverse range of application areas. Here, we demonstrate how the model is instantiated to enable a structural digital twin of an unmanned aerial vehicle (UAV). The digital twin is calibrated using experimental data from a physical UAV asset. Its use in dynamic decision-making is then illustrated in a synthetic example where the UAV undergoes an in-flight damage event and the digital twin is dynamically updated using sensor data. The graphical model foundation ensures that the digital twin calibration and updating process is principled, unified and able to scale to an entire fleet of digital twins.

42 ENGINEERING↗

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 OSTI2024

Concept Study of Robotic Camera-Based Foreign Object Detection for EV Wireless Charging

Wireless charging of an electric vehicle (EV) is an emerging charging technology promising convenient, autonomous, and highly efficient EV charging without requiring heavy gauge cables. However, due to the strong electromagnetic field created by this process that surrounds the wireless charger, the presence of foreign objects can detrimentally interact with it, thus affecting wireless power transfer (WPT) performance or leading to harmful and unwanted safety risks. This paper presents the results for a concept study on a robotic camera-based foreign object detection (FOD) system, as a supplement to the industry-existing overlapped FOD coil array method, for EV wireless charging. A Raspberry PI 4 control board and compatible Raspberry PI Camera Module 2 are used to implement camera-based object detection. The FOD program was developed using a state-of-the-art deep learning object detection model with the OpenCV and Pytorch library and is compatible with camera module hardware. A dry-run test with Raspberry PI and a camera module was conducted and the preliminary FOD function was verified. The feasibility assessment is also validated by comparing the performance of five existing state-of-the-art deep learning object detection models for vehicles, animals, persons, and metals subsets, respectively. Satisfactory performance on the benchmark datasets is observed by the tests, but further improvements are needed in future work when detecting small-sized metallic objects. A programable robotic car is also under development as ongoing work for carrying the Raspberry PI and camera module while moving for the maintenance process.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Interactive Web Application for Traffic Simulation Data Management and Visualization

As traffic simulation software becomes more effective for realistically simulating and analyzing traffic dynamics and vehicle interactions on the mesoscopic and microscopic level, the management, dissemination, and collaborative visualization of traffic simulation results produced by individual transportation planners presents a significant challenge. Existing online content management systems have a very limited capability in allowing users to query specific traffic simulation scenarios and geospatially visualize simulation results through shareable and interactive web interfaces. This paper presents a web-based application for promoting the archiving, sharing, and visualization of large-scale traffic simulation outputs. The application is developed to enhance cyber-physical controls, communications, and public education for collaborative transportation planning. Unique features of the web application include: (a) allowing users to upload their new traffic simulation scenarios (parameters and outputs), as well as search existing scenarios using easily accessible interfaces; (b) optimizing simulation output files with heterogeneous data formats and projected coordinate systems for web-based storage and management using a scalable and searchable data/metadata standard; (c) standardizing user-uploaded simulation outputs using web interfaces and data processing libraries with parallel computing capacity; and (d) providing shareable web visual interfaces for visualizing the traffic flow and signal information stored in simulation outputs (e.g., regional traffic patterns and individual vehicle interactions) and visually comparing multiple simulation outputs both spatially and temporally. Furthermore, the paper presents the conceptual design and implementation of this application, and demonstrates the application’s performance for sharing, comparing, and visualizing simulation outputs from VISSIM and SUMO, two commonly used traffic simulation software programs.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

DOE OSTI2023

Biological toxicity and environmental hazards associated with PLGA nanoparticles

There have been tremendous advances in nanotechnology. More recently, the use of nanoparticles has expanded to applications including materials, packaging, energy, and medical uses such as drug delivery, diagnostics, and therapeutics. The American Society for Testing and Materials (ASTM) and the International Organization for Standardization (ISO) define nanoparticles as particles with at least one dimension measuring between 1 and 100 nm (2), but this view is generally too limited, and recommendations have been made to consider all materials with a dimension measuring under 1,000 nm as nanoparticles. The biomedical uses of nanoparticles are particularly promising because of their ability to reach and target various sites and organs. However, some nanoparticles can be composed of toxic materials or are limited by issues of biodistribution and bioaccumulation, which have hampered their use in biomedicine. The copolymer poly lactic-co-glycolic acid (PLGA) has gained use in biomedical applications as a delivery system because it is considered biocompatible and can be formulated with controlled degradation in physiological environments. PLGA has a history in biomedicine that dates to the 1970s when biodegradable sutures were developed using PLGA. In addition, the United States (US) Food and Drug Administration (FDA) and the European Medicine Agency (EMA) have approved various PLGA particle formulations as therapeutic delivery vehicles. Interest in biocompatible materials to deliver a range of therapeutic drugs, proteins, nucleic acids, and other molecules has risen recently. In addition to drug delivery, sustained drug release can be achieved by tuning the physical properties of PLGA, such as the molecular weight, ratio of lactic to glycolic acid, drug concentration, stabilizing molecules, and particle size. Given the rise of nanoparticles, human and environmental exposure to them is inevitable as more applications use free, unbound, and highly mobile particles. Although PLGA is generally considered safe, a detailed understanding of how PLGA and the other components used to help formulate this copolymer into a nanoparticle delivery vehicle is useful for assessing potential harmful effects. Despite recent advances in PLGA nanoparticle formulations, residual stabilizing molecules, inconsistent preparations, and batch-to-batch variations can lead to toxicity. Poor preparations of PLGA can lead to common mechanisms of toxicity observed with nanoparticles, such as inflammation and oxidative stress. Consistency in PLGA formulations and accurate methods to evaluate nanoparticle toxicity are needed to ensure safety. In order to better assess PLGA nanoparticles as non-toxic delivery systems, it is critical to understand their physical and chemical properties and the formulation protocols that may introduce toxic components into particles.

Biology, nanoparticle, toxicity↗

DOE OSTI2023

An Architectural Survey of the Area 25 Nuclear Rocket Development Station, Nevada National Security Site, Nye County, Nevada, Volume 3 Of 3

The purpose of the current architectural survey is to record the Nuclear Rocket Development Station (NRDS) district, which is recommended eligible for listing to the NRHP under all four criteria as the testing center for the Rover/NERVA (Nuclear Engine for Rocket Vehicle Application) program from the initial boundary survey in 1956 to the end of nuclear rocket development on January 5, 1973. Resources in the NRDS district were evaluated to determine if they are eligible for listing to the National Register as district contributors. The current survey identified the Reactor Control Point subdistrict to provide a temporal, spatial, and functional framework for organizing the resources involved in the NRDS operations. However, the subdistrict was not evaluated as a potential historic district against the Secretary of Interior’s Significance Criteria.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

An overview of the operation architectures and energy management system for multiple microgrid clusters

The emerging novel energy infrastructures, such as energy communities, smart building-based microgrids, electric vehicles enabled mobile energy storage units raise the requirements for a more interconnective and interoperable energy system. It leads to a transition from simple and isolated microgrids to relatively large-scale and complex interconnected microgrid systems named multi-microgrid clusters. In order to efficiently, optimally, and flexibly control multi-microgrid clusters, cross-disciplinary technologies such as power electronics, control theory, optimization algorithms, information and communication technologies, cyber-physical, and big-data analysis are needed. This paper introduces an overview of the relevant aspects for multi-microgrids, including the outstanding features, architectures, typical applications, existing control mechanisms, as well as the challenges.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Development and Evaluation of Velocity Predictive Optimal Energy Management Strategies in Intelligent and Connected Hybrid Electric Vehicles

In this study, a thorough and definitive evaluation of Predictive Optimal Energy Management Strategy (POEMS) applications in connected vehicles using 10 to 20 s predicted velocity is conducted for a Hybrid Electric Vehicle (HEV). The presented methodology includes synchronous datasets gathered in Fort Collins, Colorado using a test vehicle equipped with sensors to measure ego vehicle position and motion and that of surrounding objects as well as receive Infrastructure to Vehicle (I2V) information. These datasets are utilized to compare the effect of different signal categories on prediction fidelity for different prediction horizons within a POEMS framework. Multiple artificial intelligence (AI) and machine learning (ML) algorithms use the collected data to output future vehicle velocity prediction models. The effects of different combinations of signals and different models on prediction fidelity in various prediction windows are explored. All of these combinations are ultimately addressed where the rubber meets the road: fuel economy (FE) enabled from POEMS. FE optimization is performed using Model Predictive Control (MPC) with a Dynamic Programming (DP) optimizer. FE improvements from MPC control at various prediction time horizons are compared to that of full-cycle DP. All FE results are determined using high-fidelity simulations of an Autonomie 2010 Toyota Prius model. The full-cycle DP POEMS provides the theoretical upper limit on fuel economy (FE) improvement achievable with POEMS but is not currently practical for real-world implementation. Perfect prediction MPC (PP-MPC) represents the upper limit of FE improvement practically achievable with POEMS. Real-Prediction MPC (RP-MPC) can provide nearly equivalent FE improvement when used with high-fidelity predictions. Constant-Velocity MPC (CV-MPC) uses a constant speed prediction and serves as a “null” POEMS. Results showed that RP-MPC, enabled by high-fidelity ego future speed prediction, led to significant FE improvement over baseline nearly matching that of PP-MPC.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

V1G Frequency Regulation: Algorithm Development, Validation & Analysis at Scale

Researchers at Argonne National Laboratory developed and validated a high-fidelity digital twin of a smart charging (V1G) ecosystem to model the participation of up to 1,000 unique electric vehicles (EVs) in the PJM frequency regulation market. Utilizing a discrete-event framework, the simulation models complex interactions, from dynamic grid signals (updated every 2 seconds) to individual EV charging dynamics. The simulation incorporates multiple EV models created from real-world lab test data. Researchers tested multiple control algorithms to balance the dual objectives of maximizing aggregator’s revenue and driver charging needs. Results demonstrate that aggregated EVs function as a controllable, highly effective grid resource, achieving high PJM Performance Scores (80–90%). Additionally, an optimized, market-aware bidding strategy was identified as key to profitability. The platform was shown to provide drivers with an average charging discount of nearly 50%. The algorithm was further validated in the lab using production EVs and charging stations to compare simulation results with real-world performance.

Manne, Nithin↗

DOE OSTI2024

Frequency Support From Electric Vehicles for Advancing Renewable Energy Integration

The integration of renewable energy resources (RERs) in the modern power grid is increasing rapidly because of aggressive decarbonization goals, lower costs, and increased government investment. However, higher penetrations of inverter-based generation can lead to frequency stability issues because of reduced system inertia. This paper develops a framework for quantifying the contribution of electric vehicles (EVs) toward providing frequency support to the grid and thus increasing the penetration limit of renewable energy resources (RERs). EVs are considered to provide both inertial response and primary frequency response support to the grid. A stochastic approach incorporating the uncertainties associated with the behavior of EVs is developed to derive the discharge limit of EV aggregators. A multi-machine system frequency response (MM-SFR) model is developed, which incorporates the dynamic virtual inertia and droop coefficients of EV aggregators derived from the EV control modules. Frequency security constraints are developed from this MM-SFR model, which, along with the converter voltage security and low voltage ride-through constraints, are integrated within a nonlinear optimization framework to determine the RER integration limit. Here, the efficacy of the proposed approach is validated using the RTS-GMLC test system.

25 ENERGY STORAGE↗

DOE OSTI2023

Designing Low Tortuosity Electrodes through Pattern Optimization for Fast-Charging

The development of fast-charging technologies is crucial for expediting the progress and promotion of electric vehicles. In addition to innovative material exploration, reduction in the tortuosity of electrodes is a favored strategy to enhance the fast-charging capability of lithium-ion batteries by optimizing the ion-transfer kinetics. To realize the industrialization of low-tortuosity electrodes, a facile, cost-effective, highly controlled, and high-output continuous additive manufacturing roll-to-roll screen printing technology is proposed to render customized vertical channels within electrodes. Extremely precise vertical channels are fabricated by applying the as-developed inks, using LiNi 0.6 Mn 0.2 Co 0.2 O 2 as the cathode material. Additionally, the relationship between the electrochemical properties and architecture of the channels, including the pattern, channel diameter, and edge distance between channels, is revealed. The optimized screen-printed electrode exhibited a seven-fold higher charge capacity (72 mAh g -1 ) at a current rate of 6 C and superior stability compared with that of the conventional bar-coated electrode (10 mAh g -1 , 6 C) at a mass loading of 10 mg cm -2 . Finally, this roll-to-roll additive manufacturing can potentially be applied to various active materials printing to reduce electrode tortuosity and enable fast charging in battery manufacturing.

42 ENGINEERING↗

DOE OSTI2020

Operation, Manufacturing, and Supply Chain of Lithium-ion Batteries for Electric Vehicles

The US Department of Energy (DOE) has a rich history of funding key innovations in batteries through multiple programs, including the Energy Efficiency and Renewable Energy programs sponsored by the Vehicle Technologies Office and Advanced Manufacturing Office. These DOE-sponsored innovations have been critical in lowering the cost of lithium-ion batteries to less than $160/kWh and increasing their energy density to more than 250 Wh/kg, enhancing the nation’s electrification system and achieving higher degrees of decarbonization. These investments continue to be crucial for positioning the United States as the hub for the most cumulative battery R&D programs worldwide. However, major breakthroughs in battery manufacturing are still needed to enable an electrified future evolving to predominantly incorporate rechargeable lithium-ion batteries. This will require a strong battery manufacturing base that will not only enable cutting-edge advancements in materials and manufacturing sciences but will also allow the United States to become a world leader in this fast-growing area. This review aims at supporting DOE’s Advanced Technology Vehicle Manufacturing Loan Program to give technology background and information that can be used to develop the basis for loan topics and evaluate battery applications. Such a program can represent a significant stride toward reinforcing the US position in advanced manufacturing by introducing artificial intelligence, machine learning, and sensing and smart controls to facilitate, expedite, and lead the battery industry by 2030.

25 ENERGY STORAGE↗