By David Pownall, Vice President of Digital Energy, Schneider Electric - Medium and heavy‑duty vehicles are responsible for roughly one quarter of transport emissions in both the US and EU. As these sectors rapidly electrify, fuelling this transition hinges on dependable, efficient, and scalable fast‑charging infrastructure, especially as electric truck sales surged by 80% 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 scheduling 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 CO₂ 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 integration. A coordinated, systems-based approach ensures these elements function synergistically 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 flows, as well as supporting 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.