The adoption of electric vehicles (EVs) is increasing in several countries, especially in the European Union, which produces more than a quarter of all EVs launched globally. At the same time, McKinsey analysis shows that around 375,000 charging stations exist throughout the continent. There is a crescent challenge to invest in more infrastructure to better accommodate the extensive EV adoption through all countries of the block, with estimates indicating that by 2030 they will need 3,4 million charging stations, almost ten times more compared to current numbers.
While there is a real need to implement new EV charging equipment, the existing public charging infrastructure also requires attention. Assuring that the current state of charging stations is good and that they work properly avoids malfunction, downtime, customer dissatisfaction, and loss of revenue for operators. But what exactly should companies look for when maintaining their sites, and how to perform maintenance in a cost-effective, future-proof manner? This is what TSG, as an expert in providing services for mobility solutions for the last 50 years, brings you through in this article.
Why is it important to conduct maintenance of charging infrastructure?
EV chargers are used by hundreds of drivers every month, so there is natural wear and tear caused by their use, especially regarding cables. When incorrectly connected to the charger, its cable might end up on the floor or get wrongly positioned in the socket. Also, either stretching the cable (for vehicles parked at a long distance) or curving it (for cars that are too close to the charger) can, respectively, stress and overheat the cables and decrease their service life.
In addition, chargers are usually located in the open air, where they are affected by weather changes that may vary with temperature spread over 50 degrees Celsius in some locations – enduring sun, rain, and, at times, snow. Chargers placed next to the ocean suffer from corrosion, as salt and sand damage electronic components and the steel, copper and connections of the equipment.
The pure and regular usage of chargers provokes temperature changes inside the charger casing from 40 to 60 degrees Celsius. Even with high-quality components, this abrupt temperature variation affects component materials, causes thermal dilatation and, with time, leads to electrical and mechanical problems. Some chargers rely on an internal air-conditioning system that protects them but adds another layer of complexity in terms of wear and tear. Other chargers rely on forced air cooling and sensor; check that temperature will remain in acceptable ranges. These factors make it necessary to perform regular checks (both electrical and mechanical) on the charging infrastructure to keep it available and in good condition for customers.
Moreover, the so-called preventive maintenance is of the outmost importance to put in place a strategy for predictive and corrective maintenance. Whenever chargers are not functioning well, it is essential to act fast and efficiently in order to have the equipment operating correctly again, to minimise the number of complaints, and, in the worst case, to avoid damaging the operators’ brand reputation.
How to efficiently maintain the infrastructure of EV sites?
Maintenance does not only provide repair to equipment; it also makes it safe to use. While each EV charger may require a different frequency of revision, depending on its location or frequency of usage, it is fundamental to assess all components and functions periodically. For that, there are three types of maintenance: preventive, predictive, and curative.
Preventive maintenance: the equipment doesn’t have specific issues or complaints, but a periodic check happens at a specified frequency or according to defined parameters;
Predictive maintenance: the chargers don’t have issues reported, but their key metrics present degradating trends, seen through a constant monitoring system running in the background, while the equipment is in use;
Curative maintenance: it happens after a reported issue prevents the equipment to work normally. It requires either repairing or replacing one/a few pieces or, in some cases, the entire equipment to normalize the service.
Maintenance types differ depending on the charger typology, and the architecture of its system. In the case of supervision and payment systems connected to the charger, for instance, the recommendation is to perform predictive maintenance, as it can constantly monitor the service, such as the availability of the connection. In this case, there is usually a mobile connection between the charger and a back office system to perform constant monitoring. At the sign of any malfunction, the machine sends a notification and requests an intervention.
The internal filters, fans and airflow also need to be verified regularly through preventive maintenance, even when there are no visible issues, depending on the usage frequency of the chargers and their location. They must work correctly to avoid high temperatures inside the equipment, which can then damage the power electronic and the charge itself.
How often is it necessary to do maintenance on the charging infrastructure?
As with the type of maintenance, the frequency also varies according to the general conditions of the infrastructure. In warm locations for most of the year, chargers require more frequent maintenance than in more temperate areas. While the latter can be serviced more frequently than once a year, for example, the recurrence will be determined by the owner of the charging station on the recommendation of the manufacturer. Specific regulations may also apply, depending on countries imposing minimum frequency of control.
The more stress the charger is put through, the more it requires maintenance. Several aspects need to be revised mechanically and electrically to guarantee the good functioning of the equipment. TSG has extensive and recognised expertise to provide advice regarding the recurrence and type of maintenance needed in every EV charging site and for most of the well-established brands of DC ad AC chargers in Europe.
What happens if the maintenance does not take place at the right frequency?
A poorly maintained EV infrastructure can end up being used for less time than it would if it had proper revisions over the years. It can also result in more damaged parts in the charger, which results in the obligation of switching the pieces or the entire equipment. Once there is damage, business owners need to either replace AC chargers or change parts of DC chargers that had problems, which culminates in more costs for the business.
The lack of proper maintenance can also rise major concerns for the operator company’s reputation, in particular when malfunctions are frequent and happen in many different locations. More and more customer associations are monitoring the CPO’s Network uptime statistics and creating benchmarks among CPOs on the availability of their charging equipment.
TSG is your partner in maintaining EV infrastructure
TSG has over 50 years of experience in providing service and equipment for the installation and maintenance of Forecourts across 30 countries in Europe and Africa. TSG Charge and its more than 1000 electrical experts across Europe support our customers to transition towards cleaner and more sustainable energies for mobility, tackling together the challenges of the new electrical world.
With TSG Charge, TSG builds e-Mobility solutions that fit the needs of your business. Our Charge experts can advise you on the type and number of chargers you can install on your site, the maintenance strategy they require, where chargers are best placed, and which specific local requirements or regulations you should take into account.
TSG Charge aims at creating the best e-Mobility experience for you and your customers.
