The study presents a comprehensive analysis of the integration of Photovoltaic (PV)/wind systems with electric vehicle (EV) charging stations, enhanced by green hydrogen production based on existing EV load profiles across Kentucky. It explores the use of excess PV energy to charge Lithium-ion batteries, potentially supplemented by on-grid power during periods of lower electricity costs. The research includes the development of predictive models for hydrogen production and its subsequent use in hydrogen-powered vehicles. The techno-economic assessment reveals that such integration exhibits consistent economic viability, with minimal variations in key financial indicators like the levelized cost of electricity, payback period, and PV/wind energy fraction. The study also highlights green hydrogen production for on-grid PV/wind power charging the electrolyzer leads to the highest production cost (∼13 USD/Kg) compared to off-peak grid and a grid/PV/wind combination (∼6 USD/Kg). The projected hydrogen output is poised to support a significant number of light and heavy-duty vehicles by 2040, indicating promising potential for low-carbon transportation in Kentucky. •The techno-economic feasibility of on-grid PV-based EV charging stations is studied in Kentucky.•The historical EV load profiles are used for Li-Ion batteries during low tariff periods.•The feasibility of using excess PV energy is assessed for green hydrogen production.•The projection models of green hydrogen production are developed to assess hydrogen vehicles.