In a recent webinar, EVSE Australia provided an in-depth look into building a robust charging infrastructure for electric heavy vehicles, aimed at helping Australian businesses transition to greener operations. As electric heavy-duty trucks and buses gain traction, there’s an increasing demand for effective charging solutions that address the unique challenges associated with these large vehicles. Here’s an overview of the essential considerations and strategies for electrifying heavy vehicle fleets.
Assessing Charging Requirements for Heavy Vehicles
The journey toward a fully electric heavy vehicle fleet begins with understanding the specific requirements of these vehicles. From short-range delivery trucks to long-haul prime movers, electric heavy vehicles present diverse operational needs. Key factors to consider include the maximum charging speed (measured in kilowatts), real-life range under different payloads, and the overall vehicle weight. Calculating range with a loaded vehicle versus an unloaded one, for instance, provides realistic insights into daily operational capabilities. Many businesses choose to factor in an 80% battery range to account for battery degradation and unexpected power needs, ensuring reliability even in worst-case scenarios.
Another essential consideration is evaluating the economic impact. While the initial costs of purchasing and setting up charging infrastructure can be high, EVSE emphasises that electric heavy vehicles tend to deliver significant long-term savings due to lower operational expenses. For many organisations, the transition to electric heavy vehicles aligns with environmental, social, and governance (ESG) goals, reducing emissions and contributing to broader sustainability initiatives.
Charging Infrastructure: AC vs. DC
Choosing the right charging infrastructure is critical. EVSE offers two primary charging options: alternating current (AC) chargers, ideal for overnight charging, and direct current (DC) fast chargers, suitable for quicker top-ups during the day. Many organisations adopt a combination of both to cater to different charging needs. For instance, a long-haul truck might require a quick DC charge to remain operational throughout the day, while AC chargers can suffice for smaller vehicles or those operating on a more predictable schedule.
The choice between AC and DC chargers often depends on the vehicle’s dwell time, or the amount of time it spends parked. For fleets that operate around the clock, DC charging offers faster turnaround times. This approach ensures that vehicles remain on schedule and helps fleet operators avoid costly downtime.
Site Planning: Greenfield vs. Existing Locations
The type of site—Greenfield or existing—plays a crucial role in infrastructure planning. Greenfield sites, which are new locations that can be designed from scratch, offer greater flexibility in optimising layout, power supply, and safety features. EVSE recommends a “drive-through” layout, especially for bus depots, to facilitate seamless entry and exit for vehicles. With Greenfield sites, planners can also allocate specific transformer capacity for EV charging, reducing potential issues related to power shortages.
For existing sites, power constraints are a common challenge, and active load management systems are often necessary. These systems monitor and control the power drawn by chargers in real-time, adjusting charging rates to avoid overloading the electrical system. Load management can also prioritise essential equipment, ensuring that the infrastructure operates smoothly within the site’s power limitations.
Ensuring Efficient Charging with Advanced Load Management
Load management technology is essential for both Greenfield and existing sites, especially where power is limited. Static load control, dynamic load management, and schedule-based charging are three approaches that can help manage power effectively. Dynamic load management, for example, allows operators to monitor power usage and adjust charging rates as necessary. For fleet operators concerned about electricity costs, schedule-based charging can be particularly advantageous. By programming chargers to operate during off-peak hours, businesses can significantly reduce energy costs.
Leveraging Software for Fleet Management
Implementing software solutions for monitoring and tracking is another vital step in managing an electric fleet effectively. EVSE’s software provides fleet managers with real-time visibility of charging sessions, tracking each vehicle’s battery level, charge duration, and energy consumption. This data can be accessed remotely, allowing managers to oversee operations even when they are off-site. Additionally, the software generates detailed reports that can be used for tax purposes and help companies track their carbon offset, a valuable metric for businesses committed to sustainability.
Software also enables proactive maintenance by alerting operators to potential issues before they lead to downtime. If a charger goes offline, EVSE’s ticketing system notifies both the fleet manager and EVSE’s support team, facilitating quick resolutions.
Building a Partnership for a Successful Transition
Transitioning to electric vehicles is more than a technical upgrade; it requires a strong partnership between fleet operators and service providers. EVSE offers a partnership approach, guiding companies through each phase—from initial planning to ongoing support and maintenance. Driver training is integral to this partnership, as it ensures that drivers are comfortable with the technology and understand how to operate charging equipment safely.
Furthermore, EVSE supports businesses through change management, recognising that early experiences with EVs can shape long-term adoption. By working closely with fleet operators, EVSE aims to make the transition as smooth as possible, fostering an environment where drivers feel confident and well-prepared.
Case Studies: Real-World Applications
Several case studies illustrate the practical application of EVSE’s solutions. Eurocold, for example, implemented a mix of AC and DC chargers across multiple depots to cater to varying operational needs. They also deployed portable DC chargers for flexibility, enabling charging without significant site modifications. This adaptability is especially beneficial for companies leasing their premises, as the portable units do not require permanent installation.
Linfox, a leading logistics provider, took a targeted approach by installing a single 40kW DC charger to meet the specific one-hour dwell time required for their trucks. This solution aligns with Linfox’s strategy to electrify their fleet incrementally, allowing the company to evaluate the technology’s impact on daily operations before expanding their EV infrastructure.
Embracing Future Possibilities with Charging-as-a-Service
For companies hesitant about the upfront costs of charging infrastructure, EVSE’s Charging-as-a-Service model offers a viable alternative. This model covers hardware, software, installation, and maintenance, spreading the cost over several years and making it easier for businesses to budget for the transition. Charging-as-a-Service also reduces operational risk, as maintenance and repairs are handled by EVSE, allowing fleet managers to focus on core operations without worrying about equipment upkeep.
In summary
As Australian businesses continue to embrace electric heavy vehicles, a comprehensive and well-planned charging infrastructure will be essential. From assessing vehicle requirements to selecting the right mix of charging options and planning site layouts, EVSE’s holistic approach supports a seamless transition to electric fleets. By prioritising energy efficiency, optimising site planning, and fostering strong partnerships, EVSE is paving the way for a more sustainable, cost-effective future in heavy vehicle operations.
