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Development of a DC Distribution Testbed for High-Power EV Charging

Conference ·
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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.

Research Organization:
National Renewable Energy Laboratory (NREL), Golden, CO (United States)
Sponsoring Organization:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Transportation Office. Vehicle Technologies Office
DOE Contract Number:
AC36-08GO28308
OSTI ID:
2305472
Report Number(s):
NREL/CP-5400-86912; MainId:87687; UUID:7070c26d-e5f5-4d36-867e-2a91b9b3ce21; MainAdminId:71814
Resource Relation:
Conference: Presented at the IEEE Energy Conversion Congress and Exposition (ECCE), 29 October - 2 November 2023, Nashville, Tennessee
Country of Publication:
United States
Language:
English

References (13)

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Multifunctional test bench for the emulation and testing of electric vehicle fast-charging from urban railway power lines conference March 2015
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Optimum design of an EV/PHEV charging station with DC bus and storage system conference September 2010
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Bi-directional electric vehicle fast charging station with novel reactive power compensation for voltage regulation journal January 2015
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Fast charging infrastructure for electric vehicles: Today’s situation and future needs journal July 2018
An overview of design specifications and requirements for the MVDC shipboard power system journal January 2019
New Medium-Voltage DC Railway Electrification System journal June 2018

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Related Subjects

ADVANCED PROPULSION SYSTEMS
POWER TRANSMISSION AND DISTRIBUTION
DC distribution
ESS integration
EVSE
hardware testbed
high power charging infrastructure
P-HIL
real-time simulation