• • • ELECTRICAL VEHICLES • • •


Powering the future of electric fleets through


smart infrastructure Medium and heavyduty vehicles are responsible for roughly one quarter of transport emissions in both the US and EU


By David Pownall, Schneider Electric UK & Ireland’s VP Power Systems A


s these sectors rapidly electrify, fueling this transition hinges on dependable, efficient and scalable fastcharging infrastructure,


especially as electric truck sales surged by 80 per cent globally in 2024. Meeting this demand requires more than simply


deploying highpower chargers. Large EV fleets consume substantial power: a typical enroute charging hub or bus depot may draw multiple megawatts, comparable to powering several villages. This demand calls for integrated electrical and digital architecture capable of delivering megawattscale charging that’s reliable, optimised and costeffective.


Ensuring reliable


charging infrastructure Reliable EV charging requires more than simply installing higher-capacity chargers; it demands the development of resilient, adaptable infrastructure tailored to diverse operational needs. Enroute charging hubs, for example, must deliver rapid, on-demand power for vehicles stopping briefly, while depots require smart strategies to efficiently charge large fleets during overnight or offpeak hours. Meeting these demands at scale requires a


robust electrical foundation. This includes secure grid connections, high-capacity transformers, industrial-grade switchgear and on-site generation or energy storage systems. Any vulnerability within this infrastructure can lead to significant operational disruptions, from vehicle queueing to missed delivery schedules. To mitigate these risks, digital systems can be


deployed. By continuously monitoring uptime, managing load distribution and diagnosing faults in real time, intelligent software ensures infrastructure performs reliably under varying conditions. When integrated with resilient hardware, these digital tools enable consistent, efficient energy delivery, aligning power availability with operational demands.


Maximising performance


through hardware Beyond raw capacity, fastcharging infrastructure must combine equipment performance with intelligent operational strategies. When charging, heavy goods vehicles may demand 1MW or more


at certain sites, making a modular charging structure necessary with energy buffering and flexible load shaping. Smart load management balances charger


availability, grid load, energy tariffs and realtime usage. A prime example of this in practice is the Brookville Smart Energy Bus Depot in Montgomery County, Maryland. This converted diesel bus depot now powers an allelectric fleet of 70 buses. Its infrastructure includes a 6.5 MW microgrid with solar panels, battery storage and natural gas generation. Connected sensors and digital analytics orchestrate energy use, enabling 54 buses to charge simultaneously in around three hours. Over 25 years, this smart system is projected to avoid 160,000 tons of CO emissions. This development highlights the critical role


pairing high-performance systems with intelligent energy management plays in achieving operational excellence. Without this level of coordination, even the most advanced charging equipment can underdeliver, causing delays, increased energy costs and underutilisation. By integrating load forecasting, real-time monitoring, and adaptive controls, operators can fine-tune performance across fluctuating demand profiles, energy markets and fleet schedules.


Planning for scalability,


sustainability and cost efficiency As fleet electrification expands, EV charging infrastructure must evolve without excessive financial or environmental cost. Effective planning involves not just station deployments, but grid interconnections, operations forecasting and decarbonisation alignment. Strategic site design may include scalable


architecture, modular battery storage and integrated renewable onsite generation. Energy data systems and analytics limit unnecessary expansions while optimising existing assets. Incorporating schedulable charging (e.g.


overnight or off-peak) reduces grid strain and maximises renewable energy use.


Ensuring a coordinated


approach to infrastructure While each of the strategies mentioned aim to solve a distinct aspect of EV fast-charging infrastructure, their true value comes through


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integration. A coordinated, systems-based approach ensures these elements function in synergy rather than in isolation. Advanced solutions demonstrate how a unified


infrastructure that encompasses high-power charging hardware, energy management systems (EMS), smart sensors, on-site storage and data analytics can deliver both technical and operational measurable benefits. By aligning physical assets with digital


intelligence, an ecosystem can be created that enables the deployment of charging networks that are reliable, efficient, scalable and sustainable. This effectively ensures consistent availability while minimising operational downtime, an optimisation of energy flow, and supports future fleet growth while integrating renewable energy sources and reducing environmental impact. This holistic framework provides a robust


foundation for the long-term viability of electrified transport, particularly as the industry moves from early deployment to mass adoption.


Accelerating the shift to


sustainable mobility The scale of global EV adoption, especially among larger vehicles, will only escalate. McKinsey projects Europe alone will need over 300,000 charging points for medium and heavyduty trucks by 2030, up from roughly 10,000 today. To meet this challenge, success hinges on


building infrastructure that is dependable, performanceoriented, futureproof and aligned with grid realities. As businesses and government bodies plan fleet


electrification, prioritising these essential foundations will ensure EV charging infrastructure delivers real operational value, economic return and environmental impact while accelerating the shift toward truly sustainable mobility.


electricalengineeringmagazine.co.uk


ELECTRICAL ENGINEERING • SEPTEMBER 2025 19


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