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Electrification Technologies 2018 ANNUAL MERIT REVIEW, VEHICLE TECHNOLOGIES OFFICE 4. Electrification Technologies To strengthen national security, enable future economic growth, support energy dominance, and increase transportation energy affordability for Americans, the Vehicle Technologies Office (VTO) funds early-stage, high- risk research. The research will generate knowledge that industry can advance to deploy innovative energy technologies to support affordable, secure, reliable and efficient transportation systems across America. VTO leverages the unique capabilities and world-class expertise of the national laboratory system and works with partners across industry and academia to develop new innovations in electrification, including advanced battery technologies; advanced combustion engines and fuels, including co-optimized systems; advanced materials for lighter-weight vehicle structures and better powertrains; and energy efficient mobility technologies and systems, including connected and automated vehicles as well as innovations in connected infrastructure for significant systems-level energy efficiency improvement. VTO is uniquely positioned to address early-stage challenges due to its strategic research partnerships with industry (e.g., the U.S. DRIVE and 21st Century Truck Partnerships) that leverage relevant technical and market expertise. These partnerships prevent duplication of effort, focus U.S. Department of Energy (DOE) research on the most critical research and development (R&D) barriers, and accelerate progress. VTO focuses on research that industry either does not have the technical capability to undertake on its own—usually because there is a high degree of scientific or technical uncertainty—or it is too far from market realization to merit sufficient industry emphasis and resources. The Electrification R&D effort focuses on early-stage research to understand the potential impacts of electric vehicle (EV) charging on the nation’s electric grid. This research informs the development of communication and cybersecurity protocols; enables industry to enhance the interoperability between charging equipment, the on-board vehicle charger, and charging networks; and fosters technology innovations to improve EV refueling through extreme fast charging (including high-power static and dynamic wireless charging). A focus on extreme fast charging (XFC) research will expand understanding of the charging infrastructure and electricity grid challenges to enabling a 15-minute or less battery charge. Current direct current fast-charge equipment operates at 50-120 kW. The goal for XFC research is to enable industry to develop and deploy 350+ kW power capability that enables EVs to charge in 15 minutes or less. Electric Drive Research focuses on early stage research of extreme high-power density motor and power electronics that have the potential to enable radical new vehicle architectures by dramatic volume/space reductions and increased durability and reliability. This research emphasizes a ten-fold reduction in the volume of electric traction drive systems using high-density integration technologies, leveraging high-performance computing (HPC) for modeling and optimization, and utilizing new materials for high-density electric motors. Integration of electric traction drive systems based on power electronics and electric motor innovations is also a priority. Subprogram Feedback DOE received feedback on the overall technical subprogram areas presented during the 2018 Annual Merit Review (AMR). Each subprogram technical session was introduced with a presentation that provided an overview of subprogram goals and recent progress, followed by a series of detailed topic area project presentations. Electrification Technologies 4-1 The reviewers for a given subprogram area responded to a series of specific questions regarding the breadth, depth, and appropriateness of that DOE VTO subprogram’s activities. The subprogram overview questions are listed below, and it should be noted that no scoring metrics were applied. Question 1: Was the program area, including overall strategy, adequately covered? Question 2: Is there an appropriate balance between near- mid- and long-term research and development? Question 3: Were important issues and challenges identified? Question 4: Are plans identified for addressing issues and challenges? Question 5: Was progress clearly benchmarked against the previous year? Question 6: Are the projects in this technology area addressing the broad problems and barriers that the Vehicle Technologies Office (VTO) is trying to solve? Question 7: Does the program area appear to be focused, well-managed, and effective in addressing VTO’s needs? Question 8: What are the key strengths and weaknesses of the projects in this program area? Do any of the projects stand out on either end of the spectrum? Question 9: Do these projects represent novel and/or innovative ways to approach these barriers as appropriate? Question 10: Has the program area engaged appropriate partners? Question 11: Is the program area collaborating with them effectively? Question 12: Are there any gaps in the portfolio for this technology area? Question 13: Are there topics that are not being adequately addressed? Question 14: Are there other areas that this program area should consider funding to meet overall programmatic goals? Question 15: Can you recommend new ways to approach the barriers addressed by this program area? Question 16: Are there any other suggestions to improve the effectiveness of this program area? Responses to the subprogram overview questions are summarized in the following pages. Individual reviewer comments for each question are identified under the heading Reviewer 1, Reviewer 2, etc. Note that reviewer comments may be ordered differently; for example, for each specific subprogram overview presentation, the reviewer identified as Reviewer 1 in the first question may not be Reviewer 1 in the second question, etc. 4-2 Electrification Technologies 2018 ANNUAL MERIT REVIEW, VEHICLE TECHNOLOGIES OFFICE Presentation Number: bat918 Presentation Title: Battery and Electrification R&D Overview Principal Investigator: Steve Boyd (U.S. Department of Energy) Was the program area, including overall strategy, adequately covered? Yes, the program was covered to meet the needs of this reviewer. The material gave a very good overview of the DOE program and goals, and addressed the issues. The reviewer stated yes, and commented that the speaker did an excellent job of covering all facets of the battery and electrification research and development (R&D) efforts. Key challenges in each of the main areas of technology and how they were being addressed by ongoing research was discussed. This reviewer reported that the following were covered: lithium (Li)-ion and non-lithium battery cell development, including new low cobalt (Co) cathode and intermetallic alloy anode work; electric drive developments at higher voltages and lower costs; and grid issues, including fast charging and cybersecurity. A strong case was made for the need to reduce battery cost and charging time, along with the need to reduce cost and increase efficiency of the traction drive system to ensure large market penetration of electric drive vehicles (EDVs). This reviewer commented that concurrent grid infrastructure needs to support widespread acceptance of electric vehicles (EVs) was also addressed. As far as specific technologies are concerned, the presenter did a particularly good job of covering the wide array of outstanding work in the area of power electronics and motors for vehicle electrification. The reviewer responded positively and explained that battery life must be properly predicted for projects to be funded in the extreme fast charge Li-ion cell area. This reviewer inquired whether it is possible to develop a degradation model of various battery components so that a predictive model is developed, gets shared with stakeholders, and is tested to validate the developed model. This reviewer indicated yes and suggested the following strategy adjustments: cost of electric vehicle batteries to less than $100/kilowatt-hour (kWh) and $6/kilowatt (kW) for a 100 kW peak Electric Drive System (EDS); breakout targets by technology areas (e.g., motor, inverter, battery package, controls, and thermal systems); and breakout targets for hybrid electric vehicle (HEV), plug-in hybrid electric vehicle (PHEV), performance EV, and passenger EV. Is there an appropriate balance between near- mid- and long-term research and development? The reviewer responded positively and asserted that there is an excellent balance. The presentation addressed the very near-term 2020 to the longer-term 2030 goals, and provided future roadmap indicators for the technologies being reviewed. This reviewer stated yes. There is an appropriate balance with all three areas well covered, including nearer- term Li-ion battery development and electric drive research focused on cost reduction; mid-term advanced cell battery, high-voltage electric drive, two-phase cooling, multiphysics integration, and grid integration work; and long-term research on extreme fast charging, new materials development, and cybersecurity, The reviewer commented that there is a need to make some adjustments. Regarding $6/kW for a 100 kW peak, the reviewer provided the following link to show that HEV sales are slowing (down 19.0%) and strong electric Electrification Technologies 4-3 plugged xEVs are increasing (up 46.0%). The reviewer cited an Argonne
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