The path to an emission-free construction site Electrical construction machines require robust charging interfaces

2024-10-22

The construction sites that we know and love today are a far cry from low-noise, clean, and sustainable.

But things could also be quite different. Manufacturers of construction machines such as KTEG GmbH and system integrators such as the company Suncar AG are working together toward an emission-free construction site with great commitment. To achieve this goal, the electrical construction machines and their charging interface must meet the harsh everyday requirements. This means that they must be robust and always ready for use.

Electrically powered utility vehicles are better for people and the environment

Zero emissions – but why?

For many years, the focus of politics has been on the scale of carbon emissions in the construction industry. The construction machinery used creates a significant part of the emissions on construction sites. In other words, it is now necessary for the industry to rethink, invest, and switch to alternative drive types. To this end, building contractors are switching over to electrically powered utility vehicles. This brings new challenges to the construction site, and these are being overcome with technological expertise and an innovative spirit. With its zero-emission systems, KTEG GmbH, a company of the Kenki Technology Group, is managing a proven and holistic switchover on construction sites. “Emission-free construction machines offer many advantages for our customers. They do not emit any exhaust gases and are significantly quieter. In addition to the advantages for the climate, the environment, and people, we also clearly see the competitive advantage for our customers: many tenders from cities and municipalities will require carbon-free processes in the future”, emphasizes Timo Vestweber, Marketing and Sales Support Manager, KTEG GmbH.

Together for electrification: Rik Stellbrink and Mefer Dogan, Phoenix Contact E-Mobility GmbH; Stefan Schneider, Suncar AG; Timo Vestweber, KTEG GmbH (from left to right)

Electrified construction machines

KTEG uses existing Hitachi machines from its own group of companies for its zero-emission systems. Suncar AG provides its expertise in electrification to ensure successful implementation. Suncar is a system integrator for mobile machines and has been working with KTEG since 2019. “Phoenix Contact E-Mobility is our contact partner for the CCS charging interface on the electric vehicle. We have been in good hands with them from the very beginning”, reports Stefan Schneider, CEO, Suncar AG.

DC charging on a construction site enabled by mobile battery containers

Fully charged during the lunch break

The CHARX connect universal CCS vehicle charging inlets from Phoenix Contact enable ultra-fast charging with over 500 kW while maintaining high safety and quality standards. “Charging times on a construction site must be as short as possible. With the HPC-capable charging inlets, an 8.5 ton excavator can also be charged to 100% in just three-quarters of an hour. So, during a lunch break”, explains Vestweber.
The installed CCS charging inlets have cable cross-sections of 95 mm², enabling a charging power of up to 500 kW in boost mode. The CCS charging inlets are new to the Phoenix Contact portfolio. These have a cable cross section of 120 mm², which means that electric vehicles can be charged continuously with 375 A and in boost mode even with up to 700 A. Depending on other conditions such as the ambient temperature, the routing of the cables in the vehicle, the battery, and the application-specific charging profile, you can even charge your electric vehicle with higher charging powers of over 500 kW (>500 A/1,000 V) for short periods in boost mode.
“We first had to be convinced that DC charging works on a machine”, adds Stefan Schneider, “I myself was rather skeptical. Now, DC charging is functioning on construction sites with mobile battery containers and HPC charging stations that are brought to the machine”.

Maximum product robustness for the construction site: CHARX connect universal CCS charging inlets from Phoenix Contact

Robust charging interface for off-road and outdoors

The Phoenix Contact E-Mobility company is certified in accordance with IATF 16949. The charging inlets can be used universally in any electric vehicle and are tailored to the requirements of customers in the automotive industry. The type 1 and type 2 charging interfaces have a tested, long service life of over 10,000 insertion cycles.
The high-quality materials used ensure maximum product robustness. With their optimized and clever sealing system, the vehicle charging inlets have been successfully tested in accordance with ISO 20653. The precise temperature sensors protect the vehicle against overheating at high charging powers. This is done by means of two PT 1000 sensors at the DC contacts and in the AC area via a PTC chain. The entire charging inlet features comprehensive IP6K7 and IP6K5 degree of protection. This means that the charging inlet is therefore protected against the ingress of dust, water up to a depth of one meter, splash water, and contact. This applies both to the part installed inside the vehicle and to the front area outside, even when the charging flap is open.
In addition, the front area is protected in accordance with the IP6K6K and IP6K9K degree of protection. The ingress of dust is therefore not possible, and high-pressure and steam jet cleaning can be carried out without any problems. And this is true whether the protective caps are plugged in or open. When the charging connector is plugged in, the degree of protection of the front area corresponds to that of the plugged in and locked charging connector, which is specified as being IP44 in the standard. In this case, the front area is protected against splash water on all sides, solid foreign objects with a diameter ≥1.0 mm, and against access with a wire.

Employees on an emission-free construction site

Zero emissions and High Power Charging on the construction site – a future-oriented combination

CHARX connect universal devices are therefore suitable for applications used in very demanding environmental conditions: dust, mud, and high or low temperatures on the construction site do not pose a challenge for the charging sockets. There is therefore nothing to prevent off-road use. “Here, with our system for electrification, the charging inlet from Phoenix Contact E-Mobility and the machine from KTEG, we have created a perfect combination for the emission-free construction site”, summarizes Stefan Schneider.