Overhead charging system improves ergonomics and safety

With the growing adoption of heavy-duty electric vehicles, charging infrastructure requirements in logistics centers, transfer hubs, and bus depots are increasing. Handling high-power charging cables presents both ergonomic and operational safety challenges. igus addresses this with the e-tract DC horizontal system, which relocates cable management to an overhead configuration.

Overhead cable management to reduce risks
The system is based on a guide track installed above the vehicle, either as a standalone unit or integrated into existing structures. The power cable is arranged in a loop within the guide and moved via a controlled transport system.

When activated, the cable is automatically positioned and lowered to connect with the vehicle without significant manual effort. This configuration reduces wear, mechanical damage, and collision risks associated with floor-based solutions.

Ergonomic improvement in high-power charging
In high-power charging systems such as the Megawatt Charging System (MCS), DC cables are large and heavy—up to approximately 4 kg per meter—due to conductor size and insulation requirements.

Manual handling of these cables can lead to significant physical strain. The automated system removes this burden, improving working conditions and enabling more efficient and repeatable charging operations.

System reliability and operational continuity
By protecting cables within an overhead structure, the system reduces failures caused by abrasion or accidental damage. It also eliminates the risk of vehicles driving over cables or impacting charging infrastructure.

These factors contribute to improved infrastructure reliability and reduced downtime in logistics operations.

AC version for light vehicle applications
igus is also developing an AC version of the system for light electric vehicles, designed for environments such as parking garages. In this configuration, the guide tracks are more compact and can be installed directly above parking spaces.

The cables, which are thinner, can be automatically lowered to enable convenient connection.

Reduced risk of theft
The system also addresses cable theft, an increasing issue in charging infrastructure. With automatic retraction, cables are kept out of reach when not in use, reducing unauthorized access.

This is particularly relevant for public charging sites, service areas, port logistics, and underground parking facilities.

Impact on charging infrastructure
The combination of automated cable handling, improved ergonomics, and enhanced operational safety provides an alternative to floor-based charging systems. It supports the evolution of charging infrastructure in response to the expansion of electric mobility, contributing to improved operational efficiency.

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.igus.com