Megawatt charging is coming, but most test systems aren’t ready

Sponsored by ITECH.

As EV platforms push from 400 V to 800 V and beyond 1,000 V, engineers are facing a growing gap between charging capability and what can be safely tested in real-world conditions. 

This whitepaper unpacks the concept of “validation anxiety” and the risks tied to reliability, lifecycle performance, and grid interaction. 

It also walks through the new requirements for testing chargers, batteries, and full system integration at MW scale. Download it to understand where current test systems fall short and how to prepare for the next wave of ultra-fast charging. 

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Wawa partners with Electrify America to deploy its own branded chargers at Pennsylvania stores

For retail and convenience store chains, EV charging is gradually becoming an expected amenity.

Wawa began in 1803 as an iron foundry, then evolved into a dairy, and finally a convenience store chain with over 1,000 locations in 14 US states. The company began rolling out EV charging in 2017, and currently offers charging at some 280 of its locations.

Now Wawa has announced plans to add EV charging at an additional eight locations in Pennsylvania: Bristol, Allentown, Quakertown, Upper Darby, Phoenixville, Media, Williamsport and Reading.

These will be Wawa-branded chargers, operated by Electrify America. The chargers in Upper Darby, Phoenixville, Media, Williamsport and Reading will offer CCS and NACS connectors and charging power of 400 kW. The chargers at the stores in Bristol, Allentown and Quakertown will offer CCS connectors and 350 kW of power.

“This move to testing Wawa-branded chargers demonstrates our ongoing commitment to meeting our customers’ fueling needs,” said Chief Fuel and Development Officer Rich Makin. “We are always striving to deliver a more seamless, reliable and consistent experience for our customers.”

“The Electrify America white-label offering helps retailers establish and operate a charging network that reflects their brand, customer experience and business goals,” said Rachel Moses, Senior Director of Sales and Marketing for Electrify America.

Source: Electrify America

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ChargePoint installs overhead charging system for rental car facility at Portland’s airport

ChargePoint is deploying a new DC fast EV charging facility at Portland International Airport, for the use of car rental companies. The installation features an overhead charging system with retractable cable management that’s designed to eliminate the traditional trade-off between space and cost.

The new chargers are located in the airport’s Quick Turnaround (QTA) Facility, and will enable rental car companies to rapidly charge between rentals. The deployment includes 10 dual-port fast charging dispensers mounted overhead, allowing up to 20 vehicles to be connected simultaneously. By moving charging infrastructure above the vehicles, the design reclaims valuable ground-level space, simplifies installation, and removes the risk of vehicular damage to equipment, ChargePoint explains.

The deployment also features ChargePoint’s fleet software, which gives operators real-time visibility and control across rental car fleets, from remote monitoring and troubleshooting to intelligent charging management that adapts to operational demands.

“Airports aren’t just adopting electric mobility—they’re reshaping it,” said Rick Wilmer, CEO of ChargePoint. “As rental fleet operators add EVs to their fleets, airports face the challenge of delivering high-power charging infrastructure at scale. The Port of Portland’s investment demonstrates how fast charging can integrate into existing parking lots without sacrifices for equipment placement.”

“The innovative overhead charging system enabled us to save on installation costs by limiting the conduit and wiring needed, and helps protect against potential damage caused by vehicles in the QTA,” said Jeremiah Hartley, the airport’s Rental Car Manager.

Source: ChargePoint

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WAFIOS introduces three new operator-assistance systems for its metal-bending machines

WAFIOS, whose bending machines produce hairpins, axial flux coils, stator connection assemblies and busbars for e-mobility, has detailed three operator-assistance systems: myWAFIOS.ai, an AI assistant reached by scanning a QR code on the machine; the WAFIOS Assistant, which guides setup across two connected displays; and the Smart Pay-Off Interface (SPI), which lets a machine configure its own pay-off unit.

“A small number of experienced operators are often responsible for keeping production running, while training new employees becomes more difficult. At the same time, valuable expertise is lost if it is not systematically passed on. That’s why we need AI-powered systems that support machine operators and serve as a digital memory of our experienced operators,” said Uwe-Peter Weigmann, WAFIOS’s CEO and Spokesman of the Executive Board.

myWAFIOS.ai handles questions about machine setup, troubleshooting and tool changes. It searches technical documentation, manuals and validated knowledge from experienced WAFIOS specialists, and an operator needs only a smartphone to reach it. If the answer isn’t there, the system links to the WAFIOS Service team. The assistant runs on any mobile device and answers in multiple languages via German servers.

Underneath it is connectavo, the cloud-based maintenance platform WAFIOS has offered since 2020, which carries its own AI assistant called Conny. Communication runs through an optical QR code carrying an offline link, and the machine itself stays offline at all times, which WAFIOS says protects the machine against cyberattacks.

Two connected displays take the operator through setup on the WAFIOS Assistant. According to the company, setting up new parts previously required classroom training, and operators can complete both the setup procedure and the training through the system itself, which standardizes procedures and preserves know-how for the next generation of operators. All data remains within the customer’s own company, and the Assistant runs on all High-Performance Machines equipped with WPS 3.2 EasyWay.

SPI works further upstream, joining the pay-off and the machine into one system before production starts. The connected machine configures the pay-off unit itself, presetting the basic rotation speed and other relevant parameters from available production data. Pay-off speed, the force settings of the pay-off arm and the current operating status are among the information displayed at all times. The new generation of pay-offs carrying SPI is available for various WAFIOS wire bending, straightening and spring machines.

“With myWAFIOS.ai and the WAFIOS Assistant, we make the knowledge of our experienced employees available to everyone, anytime and directly at the machine. This shortens training times, reduces setup times, and ensures that answers to important questions are available exactly when they are needed,” said Jörg Eisele, a Member of WAFIOS’s Executive Board responsible for sales.

Source: WAFIOS

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Addionics introduces a low-temperature battery architecture for EVs and electric trucks

Addionics has introduced a battery architecture designed to increase battery operations and charging at low temperatures. The company lists extended mission capability, more usable range and faster charging among the benefits, and it names electric vehicles, trucks, defense drones, spacecraft and electric aviation as the applications.

According to the company, an EV can lose up to 40% of its range in severe winters, because a cold battery pack delivers less usable energy while the vehicle draws more for cabin heating, battery heating and thermal preparation before charging.

Electric semi-trucks demand large amounts of power from their batteries, Addionics explains, because a loaded truck carries substantial weight at a consistently high highway speed, and reduced cold-weather output could mean cutting the payload or avoiding routes in winter.

Freezing conditions can also shorten a defense drone’s mission time, reduce its operational radius and limit the power available for launch and maneuvering, according to the company.

On a space mission, keeping a battery at the right temperature in cold conditions costs heater energy, thermal hardware and additional stored energy, Addionics says. Cutting that heating requirement can create benefits across the whole spacecraft power system, including the battery, the solar array and launch mass.

The new battery architecture is built on the company’s Smart 3D Porous Current Collectors, which replace conventional flat metal foils with an engineered three-dimensional structure. The porous structure lets electrolyte and lithium ions move through the plane of the current collector, which Addionics says creates additional access pathways through the electrode, shortens effective transport distances, improves active-material accessibility and distributes electrochemical activity across a larger volume.

Lithium-ion cells fade in the cold because ion transport through the electrolyte and into the electrode slows down, raising polarization and cutting both the energy a pack can deliver and the current it can safely accept on charge. The usual remedy is heat, which costs energy and time. Addionics says its structure instead lets existing materials work more effectively at low temperatures without heating the battery or changing its chemistry.

Source: Addionics

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ABB E-mobility works with local channel partner to deliver DC fast charging in the UK

ABB E-mobility has partnered with an EV charging infrastructure provider called SaveMoneyCutCarbon (SMCC) to offer ABB’s DC fast charging products to charging operators in the UK.

As a certified ABB E-mobility channel partner, SaveMoneyCutCarbon provides in-house design, grid connection management, installation, commissioning, software and back-office management, maintenance and ongoing operational support. Customers can also take advantage of flexible financing options.

ABB E-mobility works with a selected group of channel partners across Europe. Each partner completes an onboarding and certification program before being approved to commission, service and maintain ABB chargers, ensuring consistent installation and support quality across markets.

“Bringing our DC fast charging portfolio to the UK through SaveMoneyCutCarbon gives operators a fully managed solution, from site design through to long-term operation and maintenance,” said Navin Smart Channel Account Manager, ABB E-mobility UK.

“We now deliver every stage of a charging infrastructure project in-house—from design and grid connections through to installation, software management and maintenance,” said Simon Blaaser, Head of Product & Partnerships, SaveMoneyCutCarbon. “Combined with flexible funding options, we’re helping organizations accelerate their transition to electric mobility with greater confidence and less complexity.”

Source: ABB E-mobility

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Colorado Walmart becomes the company’s 100th store to add EV fast charging

Retail behemoth Walmart has been offering EV charging at its stores for years, mostly through a partnership with Electrify America. More recently, the company has begun rolling out its own company-owned and operated EV charging network. It recently celebrated the opening of its 100th EV fast charging site, at the Walmart Supercenter in Monument, Colorado.

Walmart says its network is “designed around the customer.” Charging stalls are located steps from each store, and EV charging is integrated into the Walmart app. Walmart+ members receive discounted charging rates.

Most Walmart EV charging locations feature 8 to 16 DC fast charging stalls. The chargers are equipped with both CCS and NACS connectors, and deliver up to 400 kW of power.

“By expanding EV fast charging at Walmart locations across the country, we’re giving drivers a dependable way to charge while they’re in the store,” said Shayne Wahlmeier, Senior VP, Walmart Energy. “Reaching 100 sites is an important milestone, and our broad footprint positions us to make EV charging more accessible for communities while expanding the ways we serve our customers.”

“When a customer pulls into a Walmart to charge, we want the experience to feel as reliable and effortless as the rest of their shopping trip,” said Adam Happel, General Manager, Walmart Retail EV Charging. “We’re proud to reach 100 sites, but our focus remains on building a network customers can count on every time they charge with us.”

Source: Walmart

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