Browse Topic: Fast charging

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2021 Mustang Mach-E20AUTP08_017/1/2020
Ford's first dedicated electric platform reveals the challenges and opportunities in developing a state-of-the-art EV. The 2021 Ford Mustang Mach-E is an all-new vehicle. It's Ford's first dedicated battery electric vehicle (BEV) and it's built on an all-new electric vehicle (EV) platform. If that wasn't enough pressure on its development team, the Mach-E also leverages the Mustang nameplate traditionally reserved for iconic sports coupes and serves as a technology flagship debuting a host of new features to expand convenience and safety. One of the lead engineers has likened it to simultaneously engineering an EV, a cellphone and an SUV. “You're delivering the vehicle, that's old-school stuff, we created that at Ford. Now we've got to deliver the new-school stuff too,” explained Robert Iorio, vehicle engineering manager for the Mustang Mach-E.
Seredynski, Paul
SAE Truck & Off-Highway Engineering: October 201919TOFHP1010/3/2019
On the verge of the Digital Age Increasingly connected electrohydraulic systems and machine controls allow the high degree of controllability that's essential for automated operations. Miserly power systems Engineers push engine, transmission technologies to turn off fuel usage. All options on the table Powertrain developers who spoke at SAE COMVEC are leaving no stone unturned in their quest to trim emissions. Cab air quality: A critical component of operator comfort Focus on defining cab air quality, measuring it, and designing the needed performance into cabin designs and HVAC systems is intensifying. Expanding fast charging faster Tritium works to accelerate installation of DC fast-charging infrastructure to keep up with growing demand for commercial EVs. Editorial Word on the street at COMVEC Link digital suspension uses sensors, ECU to keep cabs stable Knapheide saves costs, time by moving vehicle life testing in-house Ford revisits OHV layout, big displacement for new commercial-truck V8 Design tools ensure component compatibility, create autonomous driving tests How HMI displays impact operator productivity in industrial vehicles Truck OEMs intensify focus on customer experience, telematics to keep fleets up and running Q&A CNH Industrial's Hubertus M. Mühlhäuser discusses separating its On- and Off-Highway businesses, big investment in Nikola
Expanding FAST CHARGING faster19TOFHP10_0510/1/2019
Tritium works to accelerate installation of DC fast-charging infrastructure to keep up with growing demand for commercial EVs. There's a potential speed bump up ahead on the road to commercial electric vehicle (EV) adoption that few people are talking about. By 2030-or maybe sooner-the demand for commercial EVs will outstrip the capacity of installed DC fast chargers (DCFC), according to Jeff Wolfe, Tritium's president of the Americas. The transportation industry will be unable to achieve the goals of electrification because there will not be enough money for capital expenditures, and there will not be enough interconnection engineers to install DCFC units. Wolfe isn't just talking about this problem-he wants to start solving it today.
Blanco, Sebastian
Flexible High-Energy Textile Lithium Battery Designed for WearablesTBMG-349738/1/2019
Researchers at Hong Kong Polytechnic University (PolyU) have developed a highly flexible, high-energy textile lithium battery that offers more stable, durable, and safe energy supply for wearable electronics with a myriad of applications, including healthcare monitoring and intelligent textiles.
Comparative Analysis of Power Pad for Wireless Charging of Electric Vehicles2019-01-08654/2/2019
Wireless charging of Electric Vehicle adhere the mutual induction to transmit power to the battery and eliminates need of wire and physical connection. Power pad design, frequency of power transfer, distance between transfer coils and alignment of transfer coils are critical challenges of EV wireless charging. Power pad design entails optimization of coil shape and size, core shape, and material of coil and core along with economic analysis. The manuscript compares the already available coil shapes, with the introduction of ferrite core across the coils to design an extremely efficient power pad for the wireless charging of EV. A 3D finite element method (FEA) is being used for analysis, due to the unconventional distribution of the flux. Only three types of coils, D, DD, and DDQ, are taken to analyze the effect of magnetic ferrite core. The comparison is made based on simulation results, magnetic flux pattern as well as data imported from the results. Ansys 3D Maxwell simulation software is used to simulate the magnetic pattern of the power pad coils. Finally, the results shows the DD type coil are having the best magnetic fields and the maximum coupling coefficient with the maximum misalignment tolerance and the ferrite core across the coils have aligned the magnetic flux pattern and slightly improved the coupling coefficient.
Ahmad, Aqueel, Alam, Mohammad Saad, Chabaan, Rakan, Mohamed, Ahmed
Sensorless On Board Cell Temperature Control for Fast Charging2019-01-07914/2/2019
Fast charging capability is one of the key requirements for the success of electric vehicles. Considering the growing energy storage capacity of automotive batteries, fast charging can only be achieved using high-power charging systems. This leads to increased power dissipation inside the battery cells. The resulting heat generation inside the battery cell is a critical effect, as cell safety, performance and life time strongly depend on cell temperature and current. This must be considered by a simultaneous current and thermal battery management strategy, which requires reliable information about the individual cell temperature. Sensorless cell temperature can be derived from the cell impedance, where the charging current profile is superimposed by an excitation current and the resulting cell voltages are observed by the battery management system (BMS). An efficient algorithm for the impedance and temperature calculation can be implemented in actual BMS. In this work, this concept is verified by fast charging experiments. The thermal properties of a prismatic cell for electric vehicle energy storage are investigated under real boundary conditions, including effects of active fluid cooling. For a more detailed thermal analysis and modeling, cell surface temperature distribution is monitored by a temperature sensor array. The internal and external cell temperature increase is analyzed for different fast charging profiles. 3-dimensional thermal modeling is used to determine the internal peak temperature from the average measured temperature for a given cell type and assembly. The results can be used to define fast charging and thermal management strategies that are optimized for safe operation and long life.
Haussmann, Peter, Melbert, Joachim
Electric Vehicle Fast Chargers Present Some Overlooked Circuit Protection ChallengesTBMG-341534/1/2019
The first mass-produced electric vehicles (EVs) hit the road late in 2010 with the introduction of the Nissan Leaf, which remains the world’s top-selling, highway-capable, all-electric car. In the United States, sales of EVs are gaining momentum, with 2017 sales up by 25% over 20161. EVs, however, are still outnumbered by roughly 300 to 1 by vehicles powered by internal combustion engines. EVs are unlikely to become fully mainstream until there is a nationwide network of charging stations that can charge a vehicle quickly enough to get travelers back on the road in a matter of minutes rather than hours.
EDITORIAL: Medium-duty trucks make headway-and headlines19TOFHP02_052/1/2019
Trucks in the medium-duty and heavy-duty pickup segments have been capturing headlines of late, with new production-vehicle launches and major product introductions at trade shows hitting at an accelerated pace. At the CES show in January, Peterbilt unveiled its fully-electric Model 220EV medium-duty truck, joining the 520EV and 579EV models already in the company's EV portfolio. The 220EV is powered by two TransPower battery packs with a total of 148 kWh and a Meritor Blue Horizon two-speed drive eAxle. A range of 100 miles and a recharge time of one hour using DC fast charging make the truck suitable for local pick-up and delivery operations. The 220EV will be delivered starting summer 2019, with six in service this year with a major customer.
Gehm, Ryan
INSIDE E-TRON19AUTP02_012/1/2019
Insights into the German approach to developing a premium-class EV. Audi has made its ambitious electromobility goals clear, saying it will offer 10 all-electric and 10 plug-in hybrid models by 2025, accounting for at least one-third of its sales. To help achieve this, the company carefully designed the all-new 2019 Audi e-tron luxury SUV to not alienate its core audience. As engineer Anno Mertens, Audi's product manager for electrification put it: “In the end, it's an Audi, it's not an electric car.” Audi's target for the e-tron (yes, the name is all lower case) is the same SUV buyer who might also have shopped for a Q7, Mertens said (the e-tron's wheelbase sits between the Q5 and Q7 in Audi's SUV lineup). To that end, early in the development process, Audi surveyed its customer base to learn just what kind of EV they would use. The questions included how many business trips they take and whether they live in detached homes or in multi-family dwellings.
Blanco, Sebastian
Battery Provides Electric Vehicles with Immunity from Climate ConditionsTBMG-3341412/1/2018
Conventional lithium-ion batteries cannot be rapidly charged at temperatures below 50 °F. Electric vehicles are popular on the West Coast because the weather is conducive to quick charging. Once the vehicles are moved to the East Coast or Canada, there is a tremendous issue with charging.
Instructions for Using Plug-In Electric Vehicle (PEV) Communications, Interoperability and Security DocumentsJ2836_201807 (Current)7/18/2018
This SAE Information Report J2836 establishes the instructions for the documents required for the variety of potential functions for PEV communications, energy transfer options, interoperability and security. This includes the history, current status and future plans for migrating through these documents created in the Hybrid Communication and Interoperability Task Force, based on functional objective (e.g., (1) if I want to do V2G with an off-board inverter, what documents and items within them do I need, (2) What do we intend for V3 of SAE J2953, …).
Hybrid - EV Committee
Cryo-Fluid Capacitor (CFC)TBMG-290346/1/2018
NASA’s Kennedy Space Center (KSC) has created the Cryo-Fluid Capacitor (CFC) that capitalizes on the energy storage capacity of liquefied gases, and the relative simplicity of high-pressure gas bottles while limiting the downfalls associated with both methods. By exploiting a unique attribute of nanoporous materials — aerogel, in this case — fluid commodities such as oxygen, hydrogen, methane, etc. can be stored in a molecular surface adsorbed state at densities on par with liquid, at low to moderate pressure, and then supplied as a gas, on-demand, to a point of interest.
Feasibility Study of Bi-directional Wireless Charging for Vehicle-to-Grid2018-01-06694/3/2018
Vehicle-to-Grid (V2G) technology is expected to play a role in addressing the imbalance between periods of peak demand and peak supply on the electricity grid. V2G technology enables two-way power flow between the grid and the high-power, high-capacity propulsion batteries in an electrified vehicle. That is, V2G allows the vehicle to store electricity during peak supply periods, and then discharge it back into the grid during peak demand periods. The authors have performed an architectural design and a modeling and simulation study for a bi-directional wireless charging system for V2G applications. This research activity aims to adapt an existing SAE J2954 compatible uni-directional system design to enable bi-directional wireless power transfer with minimum impact to system cost, while maintaining full compatibility with the requirements of SAE J2954.
Tachikawa, Kosuke, Kesler, Morris, Atasoy, Oguz
Products of Tomorrow: November 2017TBMG-2779911/1/2017
This column presents technologies that have applications in commercial areas, possibly creating the products of tomorrow. To learn more about each technology, see the contact information provided for that innovation.
An Integrated Approach for Dynamic Charging of Electric Vehicles by Wireless Power Transfer - Lessons Learned from Real-Life Implementation2017-01-90764/11/2017
The aim of this paper is to introduce a complete fast dynamic inductive charging infrastructure from the back-office system (EV management system) up to the Electric Vehicle (EV) (inductive power transfer module, positioning mechanism, electric vehicle modifications) and the EV user (User interface). Moreover, in order to assess the impact of the additional demand of inductive charging on the grid operation, an estimation of the 24-hour power profile of dynamic inductive charging is presented considering, apart from the road traffic, the probability of the need for fast charging, as well as the specifications of the proposed solution. In addition, an energy management system is presented enabling the management of the operation of the inductive charging infrastructure, the interaction with the EV users and the provision of demand response services to different stakeholders. The proposed dynamic inductive charging approach has been demonstrated within a real urban environment in order to provide useful insights regarding the experience gained from a real-field trial. The relevant practical conclusions are also discussed in this paper. Finally, a cost/benefit analysis, according to the Discounted Cash Flow (DCF) principles, is performed in order to assess the economic viability of the proposed solution.
Marengo, Luca, Karakitsios, Ioannis, Karfopoulos, Evangelos, Bustillo, Aitor, Ponsar, Marc, Del Pozo, Dionisio, Madjarov, Nikolay
EV Charge Station System Reliability Modeling and Analysis2017-01-01983/28/2017
Component failures in electrical vehicle (EV) charge stations may lead to a complete loss or reduction of charging power available to the vehicles. The multistate coherent structure is employed to model the system reliability and availability of the charging cabinet and station. The number of vehicles and the customer behavior in choosing charge port is considered in the analysis. The methodology is illustrated with a simplified charging cabinet example. The usefulness of the methodology presented in this paper to EV charge station design and service is further discussed. In summary, the framework of a multistate system reliability modeling is developed for EV charge station, which can be used for further studies. The authors believe it can find many engineering applications in EV charge station and beyond.
Zhang, Jiliang, Wozniak, Carolyn
Electrification of Public Transport with Fast Charging in Traffic Congested Cities2016-01-17183/27/2016
The utility of energy efficiency and zero-emission of electric vehicles leads the way to electrify the urban public transport bus networks in many cities around the world. The purpose of this paper is to study the operational feasibility of transition the existing conventional combustion bus fleet to Electric bus fleet. The analysis is based on the data of the bus operation in Bangkok, Thailand. Traffic congestion as occurred in Bangkok is considered in the analysis. This research is focused on Fast charging technology of Electric vehicles. Instead of slow-charging overnight, Fast-charging is used during the regular layover time of the bus operation which is called Opportunity charging. The opportunity charging allows to extend the driving range of the electric buses which is a prominent problem of electric vehicles. The result stipulates the smallest number of batteries needed to meet the route requirement which come up with outstanding efficiency in energy consumption and more spacing of bus configuration. Rather than focusing on maximizing driving range, the outcome could lead to the optimization between on-buses energy storage and available charging opportunities:
Thitacharee, Thitipat, Sripakagorn, Angkee
Communication between Wireless Charged Vehicles and Wireless EV ChargersJ2847/6_201508 (Historical)8/5/2015
This SAE Recommended Practice SAE J2847-6 establishes requirements and specifications for communications messages between wirelessly charged electric vehicles and the wireless charger. Where relevant, this document notes, but does not formally specify, interactions between the vehicle and vehicle operator. This is the 1st version of this document and captures the initial objectives of the SAE task force. The intent of step 1 is to record as much information on “what we think works” and publish. The effort continues however, to step 2 that allows public review for additional comments and viewpoints, while the task force also continues additional testing and early implementation. Results of step 2 effort will then be incorporated into updates of this document and lead to a republished version. The next revision will address the harmonization between SAE J2847-6 and ISO/IEC 15118-7 to ensure interoperability.
Hybrid - EV Committee
Smart Charging Standards for Plug-In Electric Vehicles2014-01-18234/1/2014
This paper is the fifth in the series of documents designed to identify the progress on the SAE Plug-in Electric Vehicle (PEV) communication task force that follows 2010-01-0837, 2011-01-0866, 2012-01-1036 and 2013-01-1475. The primary focus of this paper is to discuss the most recent revision of J2847/1 [1], which deals with Smart Charging applications, plus the initial release of J2847/3 [2], which can be thought of as dealing with “Smart Discharging” applications. Both documents are based on the use of the Smart Energy Profile 2.0 (SEP2) Application Protocol Standard (V1.0) which was completed by the ZigBee Alliance in April 2013. The standard was then accepted by the IEEE and subsequently released as IEEE 2030.5 [3]. SEP2 started with a Marketing Requirements Document (MRD) that J2836/1™ [4]expanded for the automotive Use Cases for Smart Charging, The MRD was then used to generate the SEP2 Technical Requirements Document (TRD) that set the automotive requirements in J2931/1 [5]. The TRD was used to generate a SEP2 Application Spec where the specific automotive sequence diagrams, signals and messages are contained in J2847/1. From the SAE progression, J2836/1™ Use Cases set the requirements for the signals and messages in J2847/1. J2836/3™ [6] contains the Distributed Energy Resource (DER) Use Cases for J2847/3 signals and messages, and J2931/1 contains the protocol requirements for all the SAE Plug-in Electric Vehicle communication documents.
Scholer, Richard A., McGlynn, Hank
Li-Ion Battery and Supercapacitor Hybrid Design for Long Extravehicular ActivitiesTBMG-171829/1/2013
With the need for long periods of extravehicular activities (EVAs) on the Moon or Mars or a near-asteroid, the need for long-performance batteries has increased significantly. The energy requirements for the EVA suit, as well as surface systems such as rovers, have increased significantly due to the number of applications they need to power at the same time. However, even with the best state-of-the-art Li-ion batteries, it is not possible to power the suit or the rovers for the extended period of performance. Carrying a charging system along with the batteries makes it cumbersome and requires a self-contained power source for the charging system that is usually not possible. An innovative method to charge and use the Li-ion batteries for long periods seems to be necessary and hence, with the advent of the Li-ion supercapacitors, a method has been developed to extend the performance period of the Li-ion power system for future exploration applications.
Bi-Directional Fast Charging Study ReportTR-OSTI-GEN_01652/1/2012
This report details the hardware and software infrastructure needed to demonstrate the possibility of utilizing battery power in plug-in hybrid electric vehicles and electric vehicles with a bi-directional fast charger to support/offset peak building loads. This document fulfills deliverable requirements for ECOtality North America's support to the Idaho National Laboratory.
Gray, Tyler, Francfort, James
Rapid Capacitor Charger for Compact Marx Generators2002-01-318110/29/2002
We are developing compact converters for rapid charging of Energy Storage Capacitors for Compact Marx Generators. Compact Marx Generators have numerous applications in Pulsed Power Systems where Pulses with amplitudes of several 100kV with ns or sub-ns rise-times are needed. One example is the generation of High Power Microwaves. Initially all energy storage capacitors in a Marx generator are charged in parallel. During the so-called erection cycle, the capacitors are connected in series. The charging voltage in the parallel configuration is around 40-50kV. Rapid charging of the capacitors in the parallel configuration will enable a high pulse repetition-rate of the compact Marx generator.
Giesselmann, M., Heeren, T.
Collisional Charging in Ice and Charge Separation in Thunderstorms2001-01-28709/11/2001
Laboratory and field studies indicate that thunderstorm electrification can be attributed to rebounding collisions between small ice particles and hail. The fundamental mechanism of charge separation has defied explanation for many years, but recent experiments offer new clues, leading to a quantitative theory of the microphysical process. The theory explains the systematic dependence of charge and mass transfer on temperature, collision speeds and growth rates that have been observed in laboratory studies. Applied to storm dynamics, the theory describes how the upper portions of thunderclouds become positively charged, while the negative charge resides on hail in the lower regions.
Dash, J. G., Wettlaufer, J. S.
Development of Optimized Fast Charge Algorithms for Lead Acid Batteries1999-01-11573/1/1999
Recent studies have demonstrated that fast charging techniques can significantly extend the effective daily range of lead acid battery powered EVs. Further, other research has shown that the total lifetime energy delivery of suitable VRLA batteries can be increased markedly through partial state of charge cycling. A research team composed of Arizona Public Service (APS), CSIRO Division of Minerals (CSIRO), Electric Transportation Applications (ETA), and Hawker Energy Products, Incorporated (HEPi) has been assembled to conduct a detailed laboratory and field program to develop operating regimes that will improve lead acid battery performance in EV applications using fast charge and PSOC operation. Research is being conducted under the cognizance of the Advanced Lead Acid Batttery Consortium, both in the laboratories of CSIRO and HEPi, and in the electric vehicle fleet of APS and ETA. Initial field testing of Hawker Genesis® 12 volt, 38 Ah modules in a US Electricar S 10 pick up truck has provided very encouraging results. The vehicle was charged using a 150 kW Norvik Minit® Charger at a maximum current of 165 amperes (5C at the 33 Ah C1 rate for the Hawker Genesis® modules). The vehicle was operated three to four cycles per day from about 20% to about 80% SOC. The battery pack delivered a total of 15,258 Ah (462 times the 1C rate) in accumulating 16,846 miles on the S10 test vehicle. Initial laboratory testing has focused on maximum charge rates and the temperature effects of hyper-charging (rates greater than 9C) lead acid batteries. Charge rates of 29C were found to fully charge Hawker Genesis® 12 volt, 13 Ah modules. However, the highest practical upper charge limit was 11C, as temperature effects presented an upper limit on practical fast charge rates. Preliminary testing has shown the combination of fast charging and partial state of charge operation in EV batteries to be very promising in terms of increasing both cycle-life and effective vehicle range. This paper details the results of initial project testing and concludes that temperature effects present an upper limit on fast charge rates and that preliminary testing indicates very beneficial resutls are obtained by the combination of fast chrging and partial state of charge operation in EV batteries.
Hobbs, Raymond, Karner, Donald, Flemming, Frank, Newnham, Russell
Performance Data from an Improved Sodium/Nickel Chloride Cell9119159/1/1991
Sodium nickel chloride batteries have been tested in electric cars over the past three years. Although the performance of the cars was satisfactory, reliability was inadequate and it became apparent that the cells needed to tolerate repeated discharges to 100% depth of discharge. A new cell design with an improved sodium electrode was developed and tests with 26 Volt modules of these cells have shown that it will tolerate hundreds of cycles to 100% depth of discharge. The capacity and resistance stability of the new cell design are described and the feasibility of rapid charging is discussed.
Sudworth, J.L., Böhm, H.
Rapid Charging Batteries for Electric Propulsion Systems7201092/1/1972
Requirements and constraints for rapid charging batteries used for both pulse load and deep cycle service are outlined. Methods for fast recharging nickel-cadmium and lead acid batteries are described. A new rapid charge concept wherein nickel-cadmium batteries are both rapid charged and reconditioned is presented. Similarly, a unique method of fast charging lead acid batteries is described and illustrated. Areas of required technology improvements in batteries and electronic control devices for rapid charge application are outlined.
Sparks, R. H.
New Techniques In Automatic Flight Control System Design6103691/1/1961
Hartog, E., Moreines, H.
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