Electromobility Charging Under High Load: Why Standard Solutions are not Sufficient for Heavy Transport

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SunGrow Deutschland GmbH

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Heavy road transport remains a key economic factor in Germany—many industries rely on it. This makes it all the more important to reduce CO₂ emissions in this sector as well. A key to this is the electrification of heavy-duty fleets. However, conventional charging solutions from the passenger car sector quickly reach their limits here.

About one-third of traffic-related greenhouse gas emissions in Germany is attributed to truck traffic. In light of increasing pressure for climate protection, heavy transport is increasingly coming into focus—not least because transportation to remote regions or by industrial companies outside cities economically cannot be avoided. However, reliance on fossil fuels can be: Heavy transport can also be made climate-friendly with electricity from renewable energy sources.

A study by the Fraunhofer ISI and the Öko-Institut shows that the electrification of heavy-duty transport offers enormous potential. Around 87 percent of all truck journeys are regional and cover a total distance of less than 150 kilometers (approx. 90 miles). The targeted expansion of charging infrastructure for e-trucks at logistics locations could, therefore, have a rapid impact. However, implementation remains technically challenging.

Why Car Technology is not Enough

Unlike passenger cars, electrified trucks, buses, and vans require significantly higher charging capacities. While electric cars typically need 11 to 22 kilowatts (kW) overnight or up to 150 kW for fast charging, large commercial vehicles currently require charging capacities of up to 500 kW for fast charging. This applies to intermediate charging on long routes as well as regional trips.

Complicating matters further is the need to consider fundamental differences in operating conditions. Fleet vehicles are almost constantly in use, leaving very narrow time windows for charging. Charging cycles must therefore be closely aligned with rest periods, route planning, and logistics processes. Environmental conditions such as ports, highway rest areas, or logistics centers also pose significant demands. In these locations, charging infrastructure must be robust against dust, moisture, salt, or temperature fluctuations.

High-Power Charging and Ultra-Fast Chargers as a Basis

To meet these requirements, special direct current (DC) charging solutions are needed. Ultra-fast chargers make it possible to quickly charge heavy-duty vehicles and are designed for continuous operation under high loads.

However, these high-performance chargers bring new challenges along with their advantages: depending on the location, complex approval and grid connection procedures are required. In addition, high charging capacities (from around 480 kW) can significantly strain the local power grid. In many countries, the grid is already at capacity in many areas, making the connection of new charging parks very difficult.

Hybrid Solutions as a Bridging Technology

One solution approach is hybrid charging systems, which combine PV systems with stationary battery storage and electric charging stations. The battery systems are placed between the grid and the charging infrastructure, buffering the electricity and balancing peak loads. This offers the advantage that vehicles can be continuously charged with self-generated green electricity, even when grid availability is weak.

In combination with efficient DC charging infrastructure, scalable systems with low operating costs and clean energy are created. The goal is a grid-relieving, robust, and flexible charging infrastructure for fleets. Sungrow has already implemented initial projects in Greece, Italy, and Bulgaria. The hybrid systems demonstrate that economic efficiency, scalability, and sustainability can be successfully combined.

Satellite-Based Charging Infrastructure as a Flexible Concept

Another approach is the so-called satellite-based charging systems. Here, a central power unit of up to 500 kW supplies several decentralized charging points, the so-called satellites. The central unit contains all the power electronics such as rectifiers, controls, and cooling. From there, the satellites are supplied with electricity.

This intelligently distributes the charging power to the connected vehicles, increasing the efficiency of the charging system, especially with varying utilization. At the same time, it saves costs in operation: the technology only needs to be centrally installed once, and the satellites are cost-effective and low-maintenance. Additionally, they can be flexibly positioned, making location planning easier. This is a significant advantage, especially for fleet owners who need to keep an eye on their operational and site costs, as it allows investments and running costs to be significantly optimized.

Intelligent Control and Artificial Intelligence

To ensure that satellite-based and hybrid charging systems function reliably even under high utilization, software plays a crucial role. Artificial intelligence (AI) is increasingly being used to efficiently manage the operation and maintenance of the infrastructure.

An example of this is AI-supported systems that continuously analyze the condition of the technology and detect early signs of component wear or impending malfunctions. Maintenance operations can thus be planned strategically, reducing downtime and ensuring stable operation.

In addition, the software enables automatic fault prediction. If a technical problem occurs or is imminent, responsible technicians or the service team are immediately notified. This improves response time and ensures greater operational safety.

Strategic Partnerships for Individual Solutions

To plan and implement such systems precisely, Sungrow works closely with fleet operators, municipal companies, and transportation firms. Direct collaboration is essential to enable adjustments to specific operational processes and ensure flexible project implementation. Particularly with depot solutions consisting of a combination of PV, battery storage, and DC charging technology, such close cooperation is a key success factor.

Conclusion: Charging Infrastructure Must be Capable of Intelligent Thinking

The electrification of heavy-duty fleets offers enormous potential to reduce CO₂ emissions in transportation. However, for the transition to succeed, more than conventional charging stations from the passenger car sector is needed. What is required are powerful systems that meet the specific demands of transport and logistics operations.

Hybrid charging solutions with buffer storage, centrally controlled satellite systems, and intelligent software for control and maintenance form the technical backbone for this transition. The key is that these systems are scalable, robust, and capable of being operated economically.

Those who invest early in well-designed charging infrastructure that not only provides energy but also thinks ahead can actively shape the transformation process in heavy-duty transport. This pays off in the long term for both businesses and the climate. (se)

*Robert von Wahl is Director of EV Charging Europe at Sungrow.

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