From 2 to 20 electric trucks in three phases

The challenge

The operator runs 16 trucks from two sites and wants the whole fleet to charge at one site at the main depot. Electrification runs in three phases: 2 trucks now, 4 in two years and 20 to 25 at full electrification. The question was how large a grid connection each phase needs, how powerful the chargers should be and how to build without digging up the yard more than once.

What we did

• Simulated each phase minute by minute with 200 to 300 km per truck per day and 1.2 to 2.0 kWh/km
• Calculated minimum power per connector, peak power and energy demand in each phase
• Assessed truck battery size for winter operation
• Proposed the location of the grid connection, substation and charging bays, and which civil works to do in phase one

Outcome

• Phase 1: 2 trucks, about 70 kW peak, 315 A connection
• Phase 2: 4 trucks, about 135 kW, same 315 A connection
• Full fleet: 20 trucks, about 525 kW, 900 A connection
• 35 kW per connector is enough overnight. Civil works and ducts for six bays done in phase one
• Battery of at least 600 kWh to cope with winter operation

Lesson

Overnight charging does not need powerful chargers. It needs the right grid connection from the start and a yard that is dug up once.

Related services

• Fleet charging infrastructure
• Simulation and design