Interoperability and Interconnection to the GridHow will the grid handle an influx of EVs?

Where will the new electricity come from? What has to happen to ensure that the technology does not become obsolete?

WPUI EV Roadmap Conference, Madison WI; Sept. 10th, 2019

Theodore Bohn(tbohn@anl.gov; 630-816-7382)

Argonne National Laboratory

Disclaimer: Images used in this presentation in no way imply product endorsement

Relevant DOE funded EV Charging Interoperability and Interconnection to the Grid Activities

DOE Grid Modernization Lab Consortium (GMLC); https://gmlc.doe.gov/projects- Task Group 1.2.2 Interoperability- Task Group 1.4.1 Standards & Test Procedures for Interconnection & Interoperability- Task Group 1.4.2 Definitions Standards and Test Procedures for Grid Services

DOE Vehicle Technology Office(VTO) Grid Integration Tech Team (GITT)- Comprised of members from utilities, vehicle OEMs, national labs, equip. mfgs.- Current projects include categorizing charging assumptions and grid impact

modeling for ‘Grid Capacity of EVs at Scale’ with Integrated Systems Analysis Tech Team (ISATT) based on EPRI studies

2

Project Summary of DOE Funded Lab Call TopicOther activities in MW+ Multiport Charging Research (Excerpt from NREL presentation): Summary of research topics. ANL leads industry engagement vehicle charging requirements task for FY2019

3

HB44-3.40 ‘Point of Sale’ Commercial Dispensing of Electricity as a Fuel (non-utility owned assets)

4

SAE J2836/1 Use Case Figures: - Red line is liquid fueling point of sale.- Green line is utility/premise ‘point of sale’ at the premise meter; edge of premises- Blue line is at the tip of the conductive charging for vehicle electricity dispensing

Seller Buyer Seller Buyer Infrastructure Vehicle

What is Argonne National Lab and the EV-Smart Grid Interoperability Center?

5

ANL was designated as the first National Laboratory in 1946, initially formed to support Enrico Fermi’s work (Univ. of Chicago) on the Manhattan Project. (CP-1 75th Anniversary)

Center for Transportation Research Some StatisticsBudget: $760MStaff: 3350Location: Lemont ILArea: 1700 acresMultidiscipline research including energy, materials, computing, nuclear, bio, etc

What is Argonne National Lab and the EV-Smart Grid Interoperability Center?

6

ANL hosts the US EV-Smart Grid Interoperability Center, in conjunction with JRC in IspraItaly, to develop and validate EV charging standards as well as research grid impacts

Some Statistics50 AC EVSEs Site-widePV Fed Charging- 80kWDC Fast Chargers: 25kW, 50kW, 200kW, 400kWWireless: 50kW

Smart Energy Plazas at bldgs 300 and 362

ANL EV-Smart Grid Interoperability Standards and Technology Development for EV Charging

7

SAE J1772-v6PEV Compliance Requirements, test equipment, procedures

SAE J2847/2-v2DC Charging CommunicationRequirements, test equipment, procedures,enabling technology

SAE J2953PEV-EVSE InteroperabilityRequirements, test equipment,procedures

SAE J2954Wireless ChargingRequirements, standard test fixture, procedures

SAE J2847/6Wireless Charging CommunicationTest equipment, procedures,enabling technology

Overlapping Areas Of Common Benefit to MD/HD Electric Vehicle Charging (≥MW and other levels)

8

DFMEA Failure Analysis

MD/HDMW+ EVCharging

Utility Connection,

Load Management

DCaaS, DC Conversion,Distribution

to EVS

Mechanized Systems, Charging Interlocks

Couplers, cables, cooling

systems, ergonomics

Infrastructureplanning services,

physical implications of

parking/charging

Sub-MW level charging, over

night, opportunity

Cyber-Everything

Sub-MW level charging (ChaoJi)

{1500v/600A=.9MW}

Sub-MWwireless

charging*

Overview of Charging Levels; Bus/truck use high power DC couplers; CCS, J3105, CharIN, manual/auto.

3000 AMPS

1500V

Commercial VehicleHigh Power

The High Power Commercial Vehicle charging standard would allow users to recharge their large, commercial vehicles (Classes 6, 7 & 8) in 20-30 minutes.

Up to 80% of Class 8 truck, carrying 500kWh, in 20 minutesUp to 4.5 MW power delivery

CCS DC charging

CCS can deliver up to around 200Amps with traditional copper cables, while higher currents are delivered via cooled cables.

Up to 80% of 100kWh battery in less than 20 minutes

Up to 350kW power delivery,Some units up to 500/800kW

1000V500

(800)AMPS

Mechanized Commercial EV Charging Systems (1MW)SAE J3105 (3 versions of pantograph/side plug)

10

DC as a Service; A Utility Infrastructure Investment(Watson Collins-EPRI graphics); Limitations on 2.5MW AC Utility Service

11

Modular/Scalable Approach to Space Constrained MW+ Multiport Charging Installations; DC Busway Using the coarse depiction here for segments of AC and DC power distribution

there are four regions of conductors/contacts- Medium voltage AC feed to charging installation (overhead, buried cables)- DC output of medium voltage-to-~1000vdc to dispensers (bus bars/busway)- DC flexible cable from dispenser to PEV (passive/active cooled), robotized?- Vehicle inlet to battery terminals (w/safety systems); vibration-cooling issues

Access to the vehicle from EVSE determines length/pathway of charging cable

13.2kVac1000vdc

DC/DC DC/DCDC/DC DC/DCDC/DC

DC as a service- Utility challenges Depot charging- vehicle inlet/control challenges

Multi-drop DC bus, dispenser-coupler challenges

Example Charging Equipment Site Layout (350kW max per port, w/local AC coupled storage)6 x 350kW=2.1MW (Someday all this will charge 1 truck)

13

Single and dual output dispensers at curb

480vac to DC power converter cabinets in back

480vac switchgear and local peak shaving energy storage

Modular Power Electronics Approach- Scalability Extrapolating Traction Drive Inverter Power Density to Future WBG/Liquid Cooled DC/DC Converters

14https://www.deere.com/assets/pdfs/common/industries/electronic-solutions/macneil-pd400-product-sheet.pdf

John Deere Electronic Systems- PD400 Dual 700vdc, 450A each continuous output, 280kVA; 30kg395 x 330 x 185mm; (17x14.5x8.2”); 1300 cm2, 24.1L volumeHypothetical 4x280kW=1.12MW, 120kg, ~100L- Target: 250kW rack mount DC/DC converter module (4x=1MW); 5U high/50kg?

http://www.paytongroup.com/webfiles/files/5000.pdf

Payton Planar Transformer20kW (100kHz), 3kg

UPS/Rectifier Chassis-like blind mate power racks

Use Cases; Facility Space Requirements for Peak Shaving Storage, Switch Gear, Power Electronics

Trenched vs overhead connections, impact in installation costs/permits Others promote stacking it up like data center UPS/storage systems (Delta Electronics) Heliox promotes pad mounted fueling islands between vehicle charging lanes

15

I-80 TA Travel Plaza,Iowa

Charging Equipment Installation Footprint Examples; Central Feed

Present Case: Heavy power electronics with larger footprint requires substantial structure above vehicles, or long cables from chargers to truck location (Daimler/Heliox example; CCS, J3105)At 20,000 lbs per 450kW station, that is 80,000lb plus structure (capital equipment cost, installation/foundation costs)

16

Charging Equipment Installation Footprint Examples; Central Feed

Future Case: Prefabricated power conversion and battery storage in shipping container footprint (3MWhr Tesla Megapack); AC-to-DC (DCaaS) located at edge of charging plaza; overhead box truss structure distributed DC power/cooling and DC/DC output regulator at each vehicle (1000lb each?), robotic coupler, cord handing units

17

Electric Bus Component Placement ExamplesBatteries on roof, in rear/front storage areas, etc

18

Examples of Vehicle Component Layout: Tesla Semi(battery placement, inlet location, power pathways) Batteries under cab, inlet just ahead of first rear axle, street side

19

DAF-Paccar Straight TruckBatteries between front/rear axles, inlet behind front wheels

‘Filler door’ access; dust/dirt protection; compatibility with robotic coupler actuators

Inlets rated for MW+ (and coexistence with CCS/other couplers)

20

21

https://chargedevs.com/newswire/mercedes-begins-real-world-testing-of-its-eactros-electric-truck-with-a-wary-eye-on-the-tesla-semi/

Daimler Truck example, emphasis on proximity of charging inlet to power distribution unit (PDU)Discussion on need/safety issue in inlet cooling

Takeaway Points: Use Cases Impact Answers, Active Load Management Matching Use Cases are Important

How will the grid handle an influx of EVs?There are many models that support the conclusion that the existing grid (generation, transmission, distribution) can support current projections of EV load growth. Dynamics of charging ‘EVs at Scale’ are the core issue (when/how) charging occurs; specifically open loop vs scheduled (managed load) charging.

Where will the new electricity come from? Some people believe that bulk generation is not the core issue but matching load to source (vehicles where adequate generation distribution is located); DER.

What has to happen to ensure that the technology does not become obsolete?In the context of ANL activities, charging standards and technology development cover interoperability and interconnection requirements that also address legacy systems. Charging coupler standards are forward looking to future needs. (CharINCoupler example of higher voltage/current; 1500vdc/3000Adc, than can be used by present sized vehicles). Better standards that are maintained/updated can avoid stranded assets for non-interoperable systems that have become obsolete.

22