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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
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 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 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 OSTI2021

Quasi-Dynamic Electromagnetic Field Safety Analysis and Mitigation for High-Power Dynamic Wireless Charging of Electric Vehicles

Dynamic wireless charging of electric vehicles (EV) is an emerging charging technology to enable non-contact wireless charging while the vehicle is moving. Compared to stationary wireless charging, in-motion wireless charging involves dynamic processes in which an EV is passing over the charging pads (transmitters). This in motion process makes the dynamic electromagnetic (EM) environment more complicated, and EM safety needs to be ensured under all circumstances. This is due to the fact that the entire vehicle body may be exposed to magnetic fields while the vehicle moves over the energized transmitter. This paper investigates several typical charging scenarios when EVs approach, pass over, and move away from the charging pads. Quasi-dynamic models, which are preliminarily verified by coils’ inductance measurements, are developed to analyze the dynamic process. Based on the quasi-dynamic analysis, shielding solutions are also studied to ensure EM safety for the dynamic wireless charging processes.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Improved Control Strategy of Grid Interface for EV High-Power Dynamic Wireless Charging

This paper proposes a control strategy for the grid interface converter in high-power dynamic wireless charging system (DWCS) to address two issues on distribution network integration. Due to the unique pulsating load profile of DWCS, load transient response capability is critical for the grid interface to maintain the dc-bus voltage stable. Besides, the inherent unbalanced situation of distribution network would lead to 2nd-order oscillations on the dc-bus voltage, which would further affect the stable operation of the entire system. In this paper, the DWCS model is developed, and the relationship between the dc-bus voltage and the input/output power is analyzed. Based on the developed model, a control strategy based on direct power control is presented. Both simulation results and hardware-in-the-loop (HIL) results demonstrate that the proposed control strategy not only improves load transient response capability, but also eliminates the 2nd-order oscillations on the dc-bus voltage under imbalanced distribution network conditions.

Zeng, Rong↗
DOE OSTI2021

Optimized Renewable Energy Integration for EV High-Power Dynamic Wireless Charging Systems

Dynamic wireless charging for electric vehicles is an emerging technology to reduce on-board battery size and extend driving range. Due to its unique characteristic of vehicle-speed-related pulse-like load profile, the high-power dynamic wireless charging system (DWCS) introduces high stress to the utility grid. In this paper, an optimization model for renewable energy integration in the DWCS is proposed to mitigate the grid impact and minimize the operation costs of the whole system. As the load profile of DWCS is related to the traffic volume and various approaching vehicle speeds, the annual average daily traffic data and a stochastic model are used to develop 24-hour load profile of DWCS. To find a tradeoff between grid impact mitigation and operation costs minimization, relationships among power demand from power grid, photovoltaic (PV) capacity, wind energy (WE) capacity and energy storage (ES) capacity are analyzed, and the optimization objective and constraints are developed. Numerical simulation results demonstrate that energy storage integration can greatly mitigate the grid impact of DWCS, and optimal ratio of PV and WE can significantly reduce the operation cost of DWCS.

Zeng, Rong↗
DOE OSTI2024

Misalignment Tolerant Three-phase Wireless Fast Charging System for Electric Vehicles

This project proposes improving the technology level of the three-phase wireless charging technology developed at Oak Ridge National Laboratory (ORNL). Successful commercialization of wireless charging systems require that they meet strict safety standards for electromagnetic field emissions and interoperability with other wireless charging technology. ORNL has previously demonstrated a 50kW three-phase wireless power transfer system with 95% efficiency. This prototype system weighed less than 50% of similar high-power wireless charging system while simultaneously exhibiting better safety characteristics. Due to better material utilization, the reduction in mass is expected to translate into similar cost reduction for the magnetic coupler. Additionally, the smaller footprint of the system can ease vehicle integration difficulties that would be encountered using other technology. Furthermore, the three-phase design can be made to operate with existing single-phase coupler design more easily and without intentional physical misalignment which would otherwise pose safety issues.This project developed ORNL’s WPT technology to satisfy the specifications and requirements for electric vehicle (EV) charging. The result of the project will be a prototype and reference design for a high-power wireless charging system—including magnetics, power electronics, and controls—serving as a baseline for product development.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Misalignment Tolerant Three-phase Wireless Fast Charging System for Electric Vehicles

This project proposes improving the technology level of the three-phase wireless charging technology developed at Oak Ridge National Laboratory (ORNL). Successful commercialization of wireless charging systems require that they meet strict safety standards for electromagnetic field emissions and interoperability with other wireless charging technology. ORNL has previously demonstrated a 50kW three-phase wireless power transfer system with 95% efficiency. This prototype system weighed less than 50% of similar high-power wireless charging system while simultaneously exhibiting better safety characteristics. Due to better material utilization, the reduction in mass is expected to translate into similar cost reduction for the magnetic coupler. Additionally, the smaller footprint of the system can ease vehicle integration difficulties that would be encountered using other technology. Furthermore, the three-phase design can be made to operate with existing single-phase coupler design more easily and without intentional physical misalignment which would otherwise pose safety issues. This project developed ORNL’s WPT technology to satisfy the specifications and requirements for electric vehicle (EV) charging. The result of the project will be a prototype and reference design for a high-power wireless charging system—including magnetics, power electronics, and controls—serving as a baseline for product development.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Modular Power Electronics Approach for High Power Dynamic Wireless Charging System

Dynamic wireless power transfer (DWPT) can provide energy to EVs in motion and extend the drive range. Upscaling the charging power to 200 kW (High Power DWPT) reduces the percentage of electrified roadway required, and the solution becomes cost-effective. To smooth the power at the battery and grid, a secondary regulation stage must be added. The DWPT system therefore relies on power electronics to interface with the coils and regulate the power flow. Designing this high power system using wide bandgap devices makes ensuring high efficiency, small size, and reliable operation very challenging, and significant engineering effort is required to build such complicated systems for large-scale installation and deployment. Here, this paper describes a modular design approach for the power electronics to achieve the 200 kW wireless power transfer. As described, the SiC power electronics building block is designed, simulated, and characterized. The approach is validated in the DWPT system to build the inverter, the rectifier, and the DC/DC converter, which demonstrated high performance and reliable operation with 188 kW power.

42 ENGINEERING↗
DOE OSTI2023

Design Considerations of DC/DC Regulator for High-Power Dynamic Wireless Charging Systems

Due to fast fluctuating input voltage, dynamic wireless charging requires a post-regulator stage for battery charging control and management. This regulator stage has a high requirement on efficiency, size as well as control performance to ensure tight regulation and fast trainset. This paper addresses the control challenges by modeling the system and designing the compensator with input voltage feedforward control. In addition, high resolution PWM is implemented to improve transient performance and current balancing among the phases. Experimental results prove the effectiveness of the proposed schemes and validates 180 kW closed-loop 4-phase operation at 99% efficiency.

Xue, Lincoln↗
DOE OSTI2021

Modular Design of Receiver Side Power Electronics for 200 kW High Power Dynamic Wireless Charging System

Dynamic wireless power transfer (DWPT) can provide energy to EVs in motion and extend the drive range. By upscaling the charging power to 200 kW (High Power DWPT), the percentage of electrified roadway reduces and the solution becomes cost-effective. However, coil coupling-coefficient variation during vehicle movement fluctuates the transferred power which is unfavorable for vehicle battery. Secondary regulation design can smooth the power but the converter design becomes very challenging due to requirement in high power, high efficiency, fast control, as well as high power density since the unit will be onboard. This paper provides the modular design approach of a 200 kW secondary side unit to achieve high performance and scalability. The DC/DC converter using SiC devices demonstrated 98.3% efficiency.

Xue, Lincoln↗
DOE OSTI2021

Analysis of Magnetic Field Emissions and Shield Requirements for Interoperating High-Power EV Wireless Charging System

In this study, the magnetic field emission (MFE) is investigated for matching (identical primary and secondary couplers) and interoperating (different couplers) 11 kW wireless charging systems (WCS). The interoperating charging pads generate higher MFE than the matching charging-pads; hence, using interoperable couplers requires a more effective shielding. In this work, different shield topologies are investigated to suppress the MFE for interoperable conditions. Four 11 kW WCSs with the unipolar (uni) and bipolar (bi) transmitter (Tx) and receiver (Rx) pads has been investigated: 1) uniTx with uniRx, 2) uniTx with biRx, 3) biTx with uniRx, and 4) biTx with bi-Rx. The studied systems are designed for 11 kW WPT3 level with Z2 airgap class (140-150 mm) resembling the standard SAE-J2954. The WCSs are simulated in finite element analysis (FEA) and validated experimentally using a 11 kW biTx-biRx system. The experimental results match with the simulation results with <5% error. The FEA results show that a biTx needs a magnetic shield, and a uniTx needs an aluminum shield to meet the MFE under all interoperability and alignment conditions.

Mohammad, Mostak↗
DOE OSTI2022

A 100-kW Wireless Power Transfer System Development Using Polyphase Electromagnetic Couplers

Wireless power transfer (WPT) is an essential technology enabling automated charging of electric vehicles with safety, convenience, and flexibility while having high efficiencies. High-power wireless charging systems will be one of the dominating charging technologies for electric vehicles (EVs) in an effort to eliminate range anxiety and reduce charging times similar to that of gas station refueling practice. Polyphase electromagnetic coupler with rotating fields is a new bipolar wireless charging pad technology that can significantly increase the surface power density (kW/m2) of wireless charging coils. This study proposes a 100-kW wireless power transfer system with a compact vehicle-side (receiver) coupler that reaches to about 0.905 MW/m2 surface power density with a transmitter rated for up to 300 kW with 0.68 MW/m2. High-frequency power electronics including the inverter and rectifier designs are included in this digest along with the hardware prototype developments and preliminary experimental results.

Onar, Omer↗
DOE OSTI2025

EVs@Scale NextGen Profiles: EVSE Characterization 2024

As part of the U.S. Department of Energy's EVs@Scale consortium, the Next-Generation Profiles (NextGen Profiles) project presents analysis and results from the characterization of high-power conductive and wireless charging infrastructure. High power charging equipment is capable of recharging electric vehicle traction batteries at power levels of 200KW and above. EVSE characterization was conducted over a wide range of DC output current and DC voltage charging for nominal and off-nominal test conditions. Test plans and procedures were developed and refined to define the test configurations and requirements, measurement parameters, and test procedures used throughout NextGen Profiles testing.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

EVs@Scale: NextGen Profiles EVSE Characterization 2025

As part of the U.S. DOE EVs@Scale consortium, the Next-Generation Profiles (NextGen Profiles [NGP]) project presents analysis and results from the characterization of high-power conductive and wireless charging infrastructure. High Power Charging equipment is capable of recharging electric vehicle traction batteries at power levels of 200KW and above. Electric Vehicle Service Equipment (EVSE) characterization involves testing over a wide range of DC charging currents and voltages during nominal and off-nominal conditions. This testing allows for a better understanding of the impact that high-power charging will have on the electric grid. A common set of standard test plans, procedures, and data requirements were applied to the characterization in this document with minor updates and improvements. This report covers all conductive characterization activities performed between October 2024 and September 2025 on the Delta Electronics 350KW Electric Vehicle Charging System, consisting of power cabinet model EIDN-U350KTA01 and dispenser model EIDD-U350SSUUAEG-350.Key Findings include: Output regulation, Efficiency and power factor, Load management, Grid Resilience, Smart Charge Management (SCM) performance, Thermal control system performance, Multi-port simultaneous charging performance, and Selected performance comparisons with other EVSEs characterized in the NextGen Profiles project. Hot and cold temperature testing was not conducted on the Delta 350KW due to laboratory limitations. Future research could include continued testing the Delta hardware under off-nominal temperature conditions including multi-port/multi-session simultaneous charge testing, in addition to collecting data on other high-power conductive chargers to augment.

25 ENERGY STORAGE↗
DOE OSTI2024

High-Power Oak Ridge Converter (ORC) for Extreme Fast Charging Applications

This project report presents a novel power converter system called Oak Ridge Converter (ORC), a patented technology developed by the Oak Ridge National Laboratory (ORNL) for XFC wireless EV charging systems. ORC integrates the grid interface converter (also known as the active front-end rectifier with power factor correction) with the high-frequency inverter stage, promoting size and cost-effective charging technology with reduced infrastructure costs. The integration of the front-end rectifier with the high-frequency inverter truly eliminates one power conversion stage and achieves more than 33% size, weight, volume, and cost reduction on the wireless charging systems. Furthermore, ORC eliminates the primary side direct current (DC) bus bulk capacitors that are usually aluminum electrolytic capacitors and replaces them with very small, cost-effective, highly reliable, and high-temperature operation-capable alternate current (AC) film capacitors. ORC is also applicable to both single-phase and poly-phase couplers. When used with polyphase couplers, ORC further improves the power density of the overall system with higher power density power electronics. Moreover, ORC is inherently bidirectional and allows the system to provide power back to the grid for grid ancillary or grid support services. The ORC, based on a patented ORNL technology, is an excellent approach to resolving the high-power charging problems as described above, which directly converts the 60 hertz (Hz) line frequency into high frequency (i.e., 85 kilohertz (kHz)) to use with a high-frequency isolation transformer or wireless charging coils while eliminating the primary side number of power conversion stages from two to one. The result of the project is a prototype and reference design for a high-power wireless charging system—including power electronics, magnetics, and thermal—serving as a baseline for product development. The proposed system results are demonstrated for 270 kW of output power, with the system's overall efficiency of 92% from the AC grid, achieving less than 3% current total harmonic distortion (THD) and around 0.99 power factor (PF).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

EVs@Scale Lab Consortium Bi-Annual Stakeholder Meeting, 17 August 2022, Golden, Colorado [Slides]

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 Biannual Stakeholder Meeting was held at NREL on August 17, 2022, 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.

33 ADVANCED PROPULSION SYSTEMS↗