“The Path to Reliable, Profitable, and Scalable Truck Charging” – Andreas Mueller from ABB E-Mobility

“Truck charging requires a comprehensive approach,” Mueller began. “It’s not just about the chargers but creating a fit-for-purpose portfolio complemented by energy and asset management to deliver a holistic solution.”

The manager identified four primary challenges in truck charging: hardware reliability, energy and fleet management, grid limitations, and predictability in usage patterns. These go beyond simple hardware considerations, extending to digital solutions and site-specific strategies.

For instance, many logistics hubs are situated in brownfield sites with restricted grid connectivity. Here, ABB’s approach involves “cost-efficient, multi-outlet charging solutions combined with dynamic power allocation and energy management,” ensuring trucks are ready for their next duty cycle while managing energy effectively.

Reliability remains a cornerstone of ABB’s offerings. In Germany’s truck tender program, downtime exceeding 15 minutes attracts significant penalties. “This level of industrial-grade reliability is unprecedented and underscores the need for an advanced asset management strategy,” Mueller asserted.

Solutions Tailored for Logistics

ABB has tailored its solutions for both middle-mile and long-haul use cases. In depots, where trucks charge at lower power over extended periods, the emphasis is on dynamic power distribution and user-friendly payment authorisation for third-party drivers. Conversely, long-haul routes demand high-power solutions. “We’ve developed megawatt charging systems (MCS) capable of delivering over 1,200 kilowatts per outlet,” Mueller explained, adding that ABB has already deployed ten proof-of-concept systems across Europe and collaborated with major truck OEMs.

A standout feature of ABB’s design philosophy is its platform-based approach. “We’ve invested in a new power electronics platform designed specifically for truck charging,” Mueller noted. This includes innovations such as cables capable of delivering 300+ kilowatts continuously without liquid cooling, reducing maintenance costs and total ownership costs.

Addressing congestion at charging sites, particularly during peak hours like lunchtime, is another priority. Mueller advocated for segregated charging setups. “Fast lanes dedicated to MCS can prevent CCS trucks from blocking high-power outlets, ensuring optimal site utilisation,” he suggests.

The Digital Backbone

Digitalisation underpins ABB’s approach. Its IoT-enabled asset management system handles everything from remote diagnostics to spare part logistics, ensuring uptime and operational efficiency. “We’ve built a platform where service partners and customers can manage service operations seamlessly,” Mueller elaborated. Additionally, ABB’s energy management tools optimise grid use, integrate renewable energy, and minimise costs. “Our resilient systems ensure we never exceed grid capacity while maintaining energy availability at the right outlets,” he stated.

Mueller concludes by stressing collaboration with OEMs, adherence to emerging standards like MCS, and a strong service network as critical to scaling truck charging. “Our mission is to enable a reliable, profitable, and scalable infrastructure,” he declares.

As logistics fleets transition to electric power, ABB’s integrated approach—combining cutting-edge hardware, digital solutions, and meticulous planning—sets the standard for a sustainable, electrified future.
This article summarises Andreas Mueller’s comprehensive vision for tackling the challenges of electrifying logistics, highlighting ABB’s innovative contributions to this transformative journey.