The electrification of medium- and heavy-duty commercial vehicles is no longer a distant dream but a reality unfolding on our roads. As electric semitrucks and other large EVs gain traction, the spotlight shifts to the electrical infrastructure that must support this transition. The power demands of these vehicles are significantly higher than those of passenger EVs, necessitating careful grid planning and management to prevent voltage drops, frequency deviations, and potential blackouts. Grid stability will require real-time balancing of supply and demand, a challenge that truck developers, utility companies, and technology firms are actively working to overcome.
Electric truck sales are accelerating globally. In Europe, over 10,000 units were sold last year, driven by ambitious policies like the European Union’s carbon dioxide standards for heavy-duty vehicles, which aim for a 90% emissions reduction by 2040. In the U.S., sales are also on the rise, with more than 1,700 trucks sold in each of the past two years. However, building the necessary charging infrastructure is a complex process. Fleet owners are installing low-power chargers at their facilities for short-range or local-delivery trucks, but the real challenge lies in creating a powerful and reliable public charging network for long-haul trucking and independent owner-operators.
Long-haul trucks require high-power chargers, ranging from 350 kW to one megawatt, to minimize downtime. The introduction of the SAE International standard for megawatt charging of EVs, J3271, earlier this year marks a significant step forward. “Megawatt charging really is the holy grail of what we’re trying to achieve,” said Patrick Macdonald-King, CEO of Greenlane Infrastructure. “It will make refueling time comparable with diesel.”
Greenlane Infrastructure LLC, a public charging network for commercial zero-emission vehicles, opened its first high-speed charging station for electric trucks in April in Colton, California. This station serves as a model for charging infrastructure and energy management, built on three core principles: starting with limits, built-in flexibility, and smart and safe operation.
The Colton station is designed to accommodate large Class 8 electric trucks with 12 pull-through lanes featuring 400 kW dual-port chargers and liquid-cooled cables. Additionally, 29 bobtail lanes offer 180-kW chargers for longer-term parking and charging. The site is engineered with precast cable trenching, allowing for future equipment expansion and upgrades to megawatt charging as fleet demand grows.
To manage energy efficiently, the site features multiple levels of load control, including ABB’s Supervisory Control and Data Acquisition (SCADA) platform, which acts as a backup to the Charger Management System (CMS). This setup helps manage peak loads more effectively and provides energy resiliency. The site’s electrical infrastructure also enables remote visibility and control, reducing downtime and supporting future growth.
The Colton charging station is more than just a truck stop; it’s a prototype for the electrification of the freight industry. By addressing complex grid challenges, implementing cutting-edge energy management solutions, and designing for future scalability, Greenlane is demonstrating what’s possible when innovation and collaboration converge.
This development could significantly shape the future of the transportation sector. As electric trucks become more prevalent, the demand for high-power charging infrastructure will grow, necessitating further advancements in grid technology and energy management. The success of initiatives like Greenlane’s Colton station could pave the way for widespread adoption of electric trucks, reducing greenhouse gas emissions and making transportation more sustainable. However, achieving this vision will require continued collaboration between truck developers, utility companies, technology firms, and policymakers to overcome the technical and regulatory challenges that lie ahead.