EV Charging Infrastructure Manufacturing worked example

Thermal Derating with derated charger or test load of 380 kW: a worked example in ev charging infrastructure manufacturing

What does the result look like when derated charger or test load reaches 380 kW? The full calculation is worked below with real intermediate numbers. a product engineer needs to understand energy/cost impact of a thermal derating test or condition

The inputs for this scenario

  • Derated charger or test load: 380 kW (raised for this scenario; the documented default is 150)
  • Thermal derating runtime: 6 hr (unchanged)
  • Blended electricity rate: 0.14 $ / kWh (unchanged)
  • Chargers or modules processed: 4 units (unchanged)

Working through the calculation

  • Applying the documented formula (Thermal derating energy cost = derated load × runtime × blended electricity rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 319 $ for thermal derating energy cost, the number this scenario is built around.
  • At this operating point the engine returns 2,280 kWh for thermal derating energy used.
  • At this operating point the engine returns 79.8 $ / unit for energy cost per charger/module.
  • At this operating point the engine returns 53.2 $ / hr for hourly thermal derating energy cost.

How this compares with the baseline

  • Against the tool's baseline example, where derated charger or test load sits at 150 kW and the headline result is 126 $, this scenario comes in 153% above the baseline at 319 $.
  • A figure at this level is achievable when derated charger or test load is genuinely sustained, not just peaked for a shift. It models steady-state energy draw only — it ignores the dynamic ramp during a real derating event, cooling-fan and chiller parasitic loads, and any regenerative recovery if the test bench feeds power back to the grid.

Results at a glance

  • Thermal derating energy cost: 319 $ (headline result)
  • Thermal derating energy used: 2,280 kWh
  • Energy cost per charger/module: 79.8 $ / unit
  • Hourly thermal derating energy cost: 53.2 $ / hr

Run it with your numbers

  • Every input above is editable in the live Thermal Derating calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.