Cost-Efficient Charging for Manufacturers: Introducing eTruck Charging 

As manufacturers electrify their fleets with electric trucks (eTrucks), the focus often shifts to procuring efficient and sustainable charging solutions. However, a critical but frequently overlooked factor in charging infrastructure is the impact of harmonics on the efficiency and longevity of electrical systems. 

Harmonics, commonly described as “noise” in electricity flow, can disrupt smooth power transmission, leading to inefficiency, overheating, and potential damage to equipment. Addressing harmonics is crucial for ensuring cost-effective and reliable eTruck charging. 

Harmonics are introduced differently in AC and DC charging systems, requiring tailored approaches:

AC Charging Systems 

• Harmonics are primarily generated by the vehicle’s onboard charger as it converts power from the grid to battery storage. 

• These harmonics can reduce power quality and disrupt the grid. 

Evolt Solution: Evolt AC chargers are designed as pass-through systems, ensuring they do not produce harmonics themselves. Standalone harmonic filters are available to mitigate vehicle-induced harmonic distortion and ensure compliance with grid standards. 

DC Charging Systems 

• AC-to-DC conversion is performed inside the charger, inherently producing some harmonics depending on the rectifier design. 

Evolt Solution: Years of testing and optimisation have ensured Evolt DC chargers are highly efficient with minimal harmonic output, reducing power quality issues compared to standard rectifiers. 

1. Impact of Existing Electrical Loads
Manufacturing sites already feature equipment prone to generating harmonics, such as:

• Variable Frequency Drives (VFDs) for motors in conveyors, pumps, and fans.
• Welding machines with high-current demands.
• Robotics and automated systems reliant on non-linear electronics.
• LED lighting and other energy-efficient systems.
• HVAC systems and UPS systems.

Without proper management, harmonics from eTruck charging may exacerbate these existing distortions, leading to inefficiencies and expensive repairs.

2. Undetected Additional Costs

• Harmonic Filters: Unplanned installations may be required to manage harmonics, increasing overall costs.
• Power Factor Correction: Chargers with poor power factors increase reactive power demands, resulting in higher energy costs or penalties. Additional equipment may be needed for correction.

3. Electrical Supply Constraints
Manufacturers often have energy contracts limiting consumption during peak times. eTruck charging can strain the grid, especially if many vehicles charge simultaneously, leading to higher costs or penalties.

4. Energy Management Challenges
Charging multiple eTrucks can overwhelm existing supply systems. Without strategic planning, this could compromise operational processes and electrification goals.

To address these challenges, Evolt employs a comprehensive strategy:

1. Harmonic Management
   • Advanced filters to mitigate harmonic loads from eTruck chargers.
   • Site analysis to identify harmonic issues caused by other equipment.
   • Solutions to ensure compliance with grid standards and protect equipment longevity.
2. Power Factor Optimisation
   • Built-in power factor correction reduces reactive power demands, minimising energy costs and improving efficiency.
3. Dynamic Load Management (DLM)
   • DLM technology intelligently distributes power across chargers based on load.
   • Helps manufacturers avoid exceeding peak power limits, aligning with energy contracts.
4. Battery Energy Storage Solutions (BESS)
   • Stores excess energy during low-cost or abundant supply periods.
   • Reduces grid dependency during peak times.
   • Enables revenue generation through demand-side response programmes.

For manufacturers transitioning to eTrucks, harmonics are a critical factor in achieving efficient and cost-effective operations. By addressing harmonics during the procurement process and adopting Evolt’s advanced solutions, manufacturers can optimise energy usage, reduce hidden costs, and seamlessly electrify their fleets, all while protecting their electrical infrastructure.