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High Current EV Charging

Many commercial and municipal fleets are turning to alternative fuel vehicles for their fleet deployments. Medium- and Heavy-duty Electric Vehicles are gaining more and more popularity as true zero-emission solutions. The manufacturers are rolling new zero-emission EV buses, trucks, and vans and Commercial and government fleets are deploying them at a growing rate.

These vehicles require high-current charging, which presents a serious challenge. Often fleet facilities are being required to make wholesale, and expensive, upgrades to the power infrastructure to provide the needed electrical power to charge these new sustainable medium- and heavy-duty vehicles. In many cases, there is a need to pay tens of thousands of dollars to utilities just for transformer upgrades so that the additional necessary power is provided.

Introducing the EVMC-HC

The Electric Vehicle Master Controller – High Current, or EVMC-HC, provides the same electrical infrastructure cost reductions offered by Cyber’s current Electric Vehicle Master Controller, or EVMC, but is uniquely manufactured for the greater electrical voltages and current of buses and trucks. Using the company’s patent-pending rotational charging capability, the EVMC-HC reduces the cost of traditional electrical infrastructure needs by up to 75% while still providing the necessary charging requirements of most fleets.

The EVMC-HC sits between the electrical panel and the charging stations, allowing a single high-current circuit to power up to four charging stations. Cyber‘s patent-pending method switches the power to multiple charging stations in a “round-robin” scenario, rotating on a programmable, timed basis. The system polls the vehicles charging status as well, and if at capacity it switches to the next bus or truck in the rotation. The EVMC-HC modular design allows for all types of high-current needs, from DC fast chargers, to heavy-duty bus or truck chargers.

Demand Charge Savings

The second challenge in deploying EV trucks and buses as part of their green initiatives is the impact of the demand charges on operational budgets. Demand charges alone may create major cost over-runs as these medium- and heavy-duty electric vehicles need a lot more power than consumer EVs. Demand Charges can be a serious impediment to fleet deployment of high-current electric vehicles as the surge in demand when connecting a large number of high-current chargers at the same time would be very large. This would result in a serious increase in the demand charge fee.

How It Works

Rotational Vehicle Charging

The current approach to EV charging requires a dedicated power line to each charging station serving the multiple vehicles. Those lines need to be run from an electrical panel all the way out to the parking area. Installation costs can be prohibitive and there is no guarantee there is room in existing electrical panels or a guarantee that there is available power from the utility company!

Cyber Switching’s system switches power to multiple charging stations in a “round-robin” scenario, so that a single electrical line can feed multiple charging stations, with power incrementally rotating on a programmable timed basis to each vehicle. The EVMC also polls the charging status prior to charging a vehicle and, if charged, moves on to the next vehicle in line.

  • Dedicated circuits are required all the way to each charging station.
  • Popular charging times will drive peak demand higher.
  • No ability to respond to Auto Demand Response.
  • EV charging power use is unmonitored and unmanaged.
  • Facility requirements are reduced up to 1/4th!
  • Peak demand is reduced up to 1/4th, as well!
  • Auto Demand Response can include EV charging systems.
  • Intelligent management of EV charging power use.
The Result:  Up to 4 times as many medium- and heavy-duty vehicles can be charged using the same facilities. Infrastructure material costs for new facilities can be reduced by up to 75%. Monthly utility bills are reduced as the impact of EV charging on peak demand is kept at a minimum. Operational costs are minimized while meeting the needs of vehicle charging.