Challenge
The e-mobility ecosystem has grown significantly over the past few decades. In the early stages, electric vehicles (EVs) faced challenges due to battery limitations, short driving range, and a lack of charging infrastructure. However, improvements in battery technology and charging networks have increased the practicality and appeal of EVs. As the industry advances, EV interoperability field testing has become essential to ensure seamless integration between vehicles and diverse charging infrastructure.
This growing need for compatibility has led to an expanding ecosystem involving EV manufacturers, charging network providers, and electric vehicle supply equipment (EVSE) manufacturers. Reliable communication between these systems is critical to delivering a smooth user experience.
According to recent reports, market analysts valued the global EV charging infrastructure market at USD 25.83 billion in 2023. They project it will grow at a compound annual growth rate (CAGR) of 25.4% from 2024 to 2030 [1].
Figure (1) illustrates the main components of EV charging infrastructure. The Charging Station Management System (CSMS) oversees charging sessions via the Open Charge Point Protocol (OCPP). OCPP enables real-time communication between EVSE and CSMS, ensuring accurate data exchange during each charging session.
Figure (1) – Components of EV Charging Infrastructure.
In 2025, an Original Equipment Manufacturer (OEM) plans to launch a new high-end EV in North America, covering the USA and Canada. With the rapid expansion of the EV charging infrastructure, potential compatibility challenges may emerge between EVs and EVSE from different manufacturers. Given the diverse set of players contributing to the e-mobility ecosystem, ensuring seamless interoperability across different EVs and charging equipment necessitates rigorous testing and validation efforts.
To address these challenges, EagleTC has partnered with the OEM to conduct ongoing field testing aimed at identifying and resolving interoperability issues specific to the USA and Canadian markets.
Solution
EagleTC assigned three dedicated test engineers and a program manager exclusively to this project. With the launch of the new EV in North America, the team designed a comprehensive testing plan to ensure broad coverage of various EVSEs across multiple states. This plan aimed to verify interoperability across a wide range of charging networks and equipment. Throughout the project, EagleTC collaborated closely with the customer and carried out the following key activities.
EVSE Selection and Coverage
To begin, EagleTC compiled a list of EVSEs for testing based on several key criteria, including manufacturer, charging network, charging speed, and geographic distribution, as shown in Table (1). In addition, the team conducted testing at various locations across both the USA and Canada. This approach ensured the inclusion of diverse charging networks and equipment manufacturers, effectively simulating a wide range of real-world conditions.
| Country | States/Provinces | Charging Networks | EVSE Manufacturers | Charging Speeds |
| USA | Michigan, Chicago, Florida, New York, Indiana, Kentucky, Washington, Ohio, Tennessee, Alabama, Georgia, North and South Carolina, Pennsylvania, Vermont, Virginia and West Virginia. | EVGO, ChargePoint, Red-E, Tesla, Volta, ChargeLab, EV Connect, Ivy, Shell Recharge, Electrify America, and ChargerSync, etc. | BTC Power,Signet ABB, Ads-Tec, eCamion, Blink, Delta, Tesla, etc. |
50KW- 350KW DC fast charge, AC Level 2. |
| Canada | Ontario and Quebec. | EVGO, ChargePoint, Red-E, Tesla, Volta, ChargeLab, EV Connect, Ivy, Shell Recharge, Electrify Canada, Flo, Circuit Electric, SWITCH, Petro-Canada, and Circle K, etc. |
Table 1 – Methodology for Populating Multiple EVSE.
Route Planning
Routes, addresses, charging station availability, charging speeds, and plug types were planned using PlugShare. Figure (2) illustrates an example of a planned route.
Figure (2) – Planned Route for Testing.
App Integration and Payment Setup:
To begin, various EV charging station apps were downloaded, and payment accounts were set up for different providers, including Electrify America, Red E, ChargePoint, EVGO, and Tesla. As a result, the team ensured full readiness for real-time testing at each charging station. For reference, Figure (3) provides an example of one of the downloaded apps.
Figure (3) – Example of Downloaded App.
Daily Testing and Data Upload
The test team conducted daily drives to specific EVSEs based on the planned routes. Test results, Vector CAN logs, photos, EVSE details, and additional observations were uploaded in real time to the customer’s portal. This allowed the customer to analyze the data immediately and provide quick feedback.
Daily Review Meetings
EagleTC held daily calls with the customer to discuss testing results, review planned routes, and align on schedules for new software releases and fixes.
Software Updates and Retesting
The Electric Vehicle Communication Controller (EVCC) received both official and pre-development software updates. After each update, the team performed retesting to confirm that identified issues had been resolved and to ensure consistent data collection.
Participation in CharIN Testival 2024
EagleTC joined the OEM engineers at the CharIN Testival NORTH AMERICA 2024 in Ohio. Our team supported live interoperability testing, captured log data, and assisted with on-site troubleshooting and investigation.
Results
Since 2024, EagleTC has partnered with the customer to conduct EV charging ground testing across North America. After completing the first major milestone, EagleTC delivered valuable insights, thoroughly documenting issues and key observations. These results helped the OEM evaluate performance and implement targeted improvements.
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Extensive EVSE Testing: EagleTC tested over 500 EVSE units across 17 U.S. states and 2 Canadian provinces, as shown in Table 1. The team uploaded test data daily, allowing the customer to review findings and trends in real time.
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Effective Issue Resolution: EagleTC worked alongside the OEM to resolve all software-related issues. The team continuously tested pre-development builds to confirm fixes and maintain performance stability. EagleTC also participated in key industry events with the OEM, providing added support and contributing to successful interoperability outcomes.
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Milestone Summary: At the conclusion of the first milestone, EagleTC compiled a clear, concise report of the test results. This summary helped the OEM quickly understand the key findings and prioritize next steps.
This project demonstrates EagleTC’s ongoing ability to:
- Deploy teams on the ground with short notice, while developing strategic plans and testing routes efficiently.
- Implement cost-effective solutions by minimizing overhead costs through efficient resource allocation, comprehensive tester training, and robust program management processes.
- Provide prompt customer support, ensuring issues and concerns are communicated in real time.
- Adapt seamlessly to changing circumstances while consistently delivering accurate and timely results.
[1] EV Charging Infrastructure Market Size & Share Report 2030, published by Grand View Research. Source: https://www.grandviewresearch.com/industry-analysis/electric-vehicle-charger-and-charging-station-market