Project 2: Electrified Roadways

July ’24 Updates

Project leads: Khurram Afridi, Cornell University, & Marv Halling, Utah State University 

Key Accomplishments for this Quarter:

  • Validation of the structural model using data obtained from the pre-pilot pavement testing of a 215 kW DWPT system at Indiana/Purdue’s Accelerated Pavement Testing (APT) facility continues. Advanced constitutive viscoelastic models have been integrated into the simulation to enhance model accuracy and replicate the viscoelastic behavior of the asphalt layer across different temperatures. Concurrently, additional modifications are underway in the in-house FE tool designed to analyze pavements integrated with a charging unit (CU), aiming to replace the current reliance on commercial FE software.  
  • Simulation of both heating in gyratory compacted asphalt mix samples of both unmodified and modified binders has been completed; the increase in temperature has been modeled successfully with FEM; Key shape parameters of temperature versus time curves have been identified; Asphalt mix samples have been tested for their Flow Numbers using unconfined dynamic tests at multiple temperatures; data from these work will be utilized to predict the relative increase in rutting potential of asphalt pavements with unmodified and modified binders as a result of an increase in temperature, if any, due to the charging units. 
  • An improved concrete mixture, Engineered Cementitious Composites (ECC), was selected for durable electrified concrete pavements due to its unique multiple micro-cracking property, promising reduction in crack width, and high fatigue resistance. Successful development of ECC and trial flexural tests have been conducted. Concrete specimen fabrication and comprehensive testing of material properties and large-scale structural panels are ongoing. In addition, numerical model development to replicate fatigue loads from passing traffic has been completed. This model will be validated using the results from the large scale tests.  
  • Structural validation was completed at the Accelerated Pavement Testing (APT) facility. 50,000 passes were conducted on both flexible and rigid sections. Among the two pavement sections, only the rigid pavement exhibited visible distress, identified as a mid-panel crack. Atypical deflection patterns in the flexible section, as observed from FWD testing, highlighted the influence of the embedded DWPT components. The thermal testing showed a rise in pavement temperature upon energization; yet this increase stabilizes over time across all thermocouple depths. An additional 25,000 passes with increased load will be conducted on both sections to further assess the development of distress. 
  • Construction of the 230-kW receiver coil, core, and shielding structure that was designed using the ASPIRE-based modeling/design approach, where performance objectives include maximizing coupling between transmitter and receiver and minimizing a sequence conversion factor, was completed. The transmitter and receiver were characterized and the compensation circuit values were determined. The compensation circuit capacitors have now been procured and are being constructed.  A subtlety of this overall design is that it required a reformulation of the boundary element model, upon which the ASPIRE three-phase models are based, to account for induced eddy currents within the shield. This approach was validated using our custom 2D finite element software.  
  • Task 2.1 has supported the contractors on the instantiation of the ASPIRE three-phase transmitters within the IN pilot roadway. Construction began on April 1st resulting in significant media coverage and public interest. The team supported a groundbreaking ceremony held at an INDOT maintenance facility adjacent to the roadway.
  • Completed room and high (50°C) temperature water diffusion tests on two epoxy materials. 
  • Performed low-velocity impact testing on the epoxy specimens before and after water diffusion AND the baseline concrete/epoxy specimens  
  • Established sealing test platform for in-situ monitoring of humidity and temperature.

Industry and Innovation Highlights:

  • Work with the associated project with INDOT has supported the contractors on the instantiation of the ASPIRE three-phase transmitters within the IN pilot roadway. Construction began on April 1st and has resulted in significant media coverage and public interest. The team supported a groundbreaking ceremony held at an INDOT maintenance facility adjacent to the roadway. They have also supported numerous requests for interviews, laboratory tours, etc.  
  • Completed INDOT’s Technical Report, scheduled for publication in the coming months. As the APT project nears completion, the team is coordinating with INDOT to conduct a series of final destructive tests before the removal of both pavement sections. 
  • Task 6 has been actively collaborating with various members of the Industry and Innovation Board (IIB), including Cummins, Central Florida Expressway Authority, Electreon, AECOM, and Purdue University, to develop a comprehensive cost estimating tool for electrified road systems. The tool is designed to include detailed cost components such as construction, power infrastructure, technology integration, and vehicle receiving pads. 

Advancements in Alleviating Barriers or Challenges to Widespread EV Adoption:

  • Our project is helping reduce the cost of electric vehicles by reducing the size of the onboard batteries and instead delivering power to the electric vehicles (EVs) wirelessly from electrified roadways. The lower cost of EVs will help with their widespread adoption.  
  • We are working on making electrified pavements more durable. This will alleviate transportation department concerns regarding the life of electrified roadways and help with their greater adoption, which in turn will enable greater adoption of EVs.
  • We are working on reducing the cost of the electrified roadways with dynamic wireless charging capability, which will enable widespread deployment of such technology and alleviate EV range anxiety. 

Advancements of Interest to Marginalized or Underserved Communities:

  • Our work on electrified roadways will result in cost reduction of electric vehicles through the use of smaller batteries, which will enable marginalized and underserved communities to own electric vehicles.
  • Our work on longer life and lower costs of electrified roadways will enable this technology to be deployed in all communities, including marginalized and underserved communities.
  • Our work on testing electrified roadways will ensure that such technology is robust and able to serve all communities, including marginalized and underserved communities.