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A new and unique electric vehicle powertrain model based on bidirectional power flow for propel and regenerative brake power capture is developed and applied to production battery electric vehicles. The model is based on a Willans line model to relate power input from the battery and power output to tractive effort, with one set of parameters (marginal efficiency and an offset loss) for the bidirectional power flow through the powertrain. An electric accessory load is included for the propel, brake and idle phases of vehicle operation. In addition, regenerative brake energy capture is limited with a regen fraction (where the balance goes to friction braking), a power limit, and a low-speed cutoff limit. The purpose of the model is to predict energy consumption and range using only tractive effort based on EPA published road load and test mass (test car list data) and vehicle powertrain parameters derived from EPA reported unadjusted UDDS and HWFET energy consumption.

This paper outlines the development and progress of implementing the SAE J2931, J2847/2 and J1772 communication standards to accomplish off-board DC charging. Communication between the off-board DC Electric Vehicle Supply Equipment (EVSE) and Plug-in Electric Vehicle (PEV) occurs on the pilot wire of the SAE J1772 connector via HomePlug Green PHY power line communication (PLC). An Electric Vehicle Communication Controller (EVCC) was developed to interface with the PEV's Battery Energy Control Module (BECM). A Supply Equipment Communication Controller (SECC) was also developed to interface with the DC EVSE's Power Control Module (PCM). Firmware was developed to implement the SAE J2931/1 communication stack, which is harmonized with the ISO/IEC DIS 15118-2 and DIN 70121 standards for DC charging communication.

The Battery Performance and Cost Model (BatPaC), developed by Argonne National Laboratory, is a versatile tool designed for lithium-ion battery (LIB) pack engineering. It accommodates user-defined specifications, generating detailed bill-of-materials calculations and insights into cell dimensions and pack characteristics. Pre-loaded with default data sets, BatPaC aids in estimating production costs for battery packs produced at scale (5 to 50 GWh annually). Acknowledging inherent uncertainties in parameters, the tool remains accessible and valuable for designers and engineers. BatPaC plays a crucial role in National Highway Transportation Traffic Safety Administration (NHTSA) regulatory assessments, providing estimated battery pack manufacturing costs and weight metrics for electric vehicles. Integrated with Argonne's Autonomie simulations, BatPaC streamlines large-scale processes, replacing traditional models with lookup tables.