Amid the ongoing electrification of heavy-duty transport and the rollout of the Megawatt Charging System (MCS), process automation is gaining strategic importance.
In this context, robotic arms are emerging as an innovative solution to optimise the charging process of electric vehicles (EVs).
Joost van der Weijde, Co-founder at ROCSYS, Dutch company specialized in autonomous charging solutions for EVs, explains: “By automating the process, we’re addressing critical ergonomic, operational, and safety challenges in heavy-duty electric transport.”
This technological advancement is primarily driven by three key technical factors: driver safety, reduction in system weight, and the automation of the connection process, which eliminates the need for manual handling and allows drivers to make better use of their mandatory rest periods.
Indeed, during the mandatory breaks set out by the Alternative Fuels Infrastructure Regulation (AFIR), the ability to charge automatically becomes a competitive advantage in logistics operations.
“Time is lost walking, connecting and disconnecting the vehicle, instead of actually resting. Driver safety is the top priority,” states Yancho Todorov, Senior Scientist and coordinator of the MACBETH project (Multipoint Megawatt Charging for Battery Electric Truck Hubs) at the VTT Technical Research Centre of Finland, the institution leading the initiative.
However, Todorov warns Mobility Portal: “Perhaps the ecosystem is not yet ready for the implementation of robotic arms.”
“The advantages are clear, but the technology itself is still in the early stages of testing and adoption. Moreover, demand for MCS charging remains low for the time being,” he adds.
It is worth mentioning that the MACBETH project – which aims to demonstrate cutting-edge solutions for megawatt systems – includes the participation of ROCSYS.
The system uses computer vision and artificial intelligence to detect and locate the vehicle’s charging port, determine the optimal way to access it, open the cover, and accurately connect the plug.
“As it’s a new product, some difficulties arise. For example, how to ensure compliance with different safety regulations,” Todorov adds.
In this framework, pilot systems will be installed, and multiple tests will be carried out to assess both user satisfaction and the impact on charging hub operations.
How does the market view robotic charging?
Mikko Pihlatie, Research Professor at VTT, states: “It’s an important step towards reinventing the entire electric transport ecosystem, from charging infrastructure to logistics operations.”
Michael Mayer-Rosa, Senior Director at Delta Electronics, also firmly believes in a robotic future.
“In Dubai, things like this are already being done,” he explains to Mobility Portal.
However, the expert explains that it is essential to overcome prejudices and address safety problems before the technology is fully prepared.
“In the future, anything is possible, but it should be something done by robotics,” Mayer-Rosa insists.
“We need to see how the market reacts,” he adds.
Other robotic charging projects
According to the Business Association for the Development and Promotion of Electric Mobility (AEDIVE), Spain is expected to invest seven billion euros in e-trucks by 2030, of which 3.4 billion euros corresponds to additional costs for switching from diesel to electric.
AFIR establishes that there must be at least 3,600 kW of power every 60 km on main roads and 1,500 kW every 100 km on secondary routes.
This implies a substantial increase in hose thickness and weight.
In light of these circumstances, solutions such as the EVOSS project promoted by the CARNET think tank are being considered.
This involves the introduction of autonomous charging robots that navigate to parked EVs, connect, and begin the refuelling process without any additional fixed installation.
Another example is that of the South Korean group Hyundai, which launched the Automatic Charging Robot (ACR) in 2023 – a robotic arm capable of automatically carrying out the necessary tasks when a car arrives at a station.
The device works with a 3D camera and has a laser sensor to detect fixed and moving obstacles, thus avoiding potential accidents.
Meanwhile, Huawei presented a similar development earlier this year, although it is aimed specifically at autonomous vehicles.
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