Enabling Efficient Operations of Electric Heavy Trucks: Practical Applications of Mobile Integrated Energy Storage and Charging Technology
Release date:
2025-12-05
Through innovative core technologies, the mobile integrated energy storage and charging system effectively addresses the challenge of refueling electric heavy-duty trucks in construction settings.
Click the blue font above to follow us.
As new‑energy construction machinery gains rapid traction, all‑electric heavy‑duty trucks are emerging as a preferred choice for construction sites thanks to their low‑emission profile. However, challenges such as insufficient power at fixed charging stations on open‑air job sites, high costs, and inconvenient refueling severely constrain operational efficiency. In particular, heavy trucks often rely on large‑capacity battery packs rated at 185 kWh, and lengthy charging times frequently result in wasted man‑hours. To address these issues, a mobile, integrated energy‑storage‑and‑charging system—offering 480 kW output and 200 kWh capacity—has been developed. With its high power and exceptional flexibility, it serves as a “mobile energy hub” for electric heavy‑duty trucks on construction sites.
Technical Solution: Integrated Design for an Efficient Energy-Replenishment System
This device is designed around the core principles of “modular integration and mobile deployment,” seamlessly integrating energy storage, rectification, and charging functions within a trailer‑mounted unit to streamline installation, transportation, and commissioning. Its key components include a 219 kWh high‑voltage battery energy storage system, a 480 kW DC‑DC rectifier cabinet, and dual‑gun 600 A liquid‑cooled charging terminals, achieving efficient energy replenishment through precise power conversion and control logic.
The rectifier cabinet is built using 16 × 30 kW DC‑DC power modules, with every two modules connected in parallel to form an output circuit. Coordinated by the Control and Communication Unit (CCU), it facilitates energy transfer from the battery system (350–550 V) to the charging terminal. The unit delivers a charging output voltage range of 200–1000 V and a maximum output current of up to 600 A, meeting the charging requirements of mainstream heavy-duty electric trucks and significantly reducing refueling time. Moreover, its trailer‑mounted design enables flexible deployment at various construction sites, eliminating reliance on fixed grid infrastructure and making it particularly well suited for outdoor operations in areas with limited or unreliable power infrastructure.
System Architecture and Functions: Multi-Module Coordination Ensures Reliable Operation
The system achieves a full‑chain closed loop for energy storage, conversion, distribution, and replenishment through the coordinated operation of the energy storage system, DC charger, power distribution unit, and charging terminal, with clearly defined functions and tight interconnection among all modules.
Energy Storage Systems: High-Density Storage and Intelligent Control
The energy storage system employs a highly integrated battery architecture, with 3.7 V/58 Ah cells configured into 4P32S battery module units (118.4 V/232 Ah). Four such modules are connected in series to form a battery cluster (473.6 V/232 Ah), and two clusters are paralleled before being interfaced with the high-voltage junction box, ultimately delivering an energy storage capacity of 473.6 V/464 Ah to meet the continuous recharging needs of multiple heavy-duty trucks. The Energy Management System (EMS), serving as the core control unit, establishes a two-tier communication topology—“centralized monitoring–device feedback”—to continuously acquire critical parameters from the Battery Management System (BMS), including voltage, current, temperature, and state of charge (SOC). When the discharge current exceeds limits or temperatures surpass thresholds, the EMS automatically disconnects the circuit breaker to ensure battery protection. Additionally, the EMS supports historical data logging, report generation, and fault alarm functions, using color-coded indicators to distinguish event severity and help operations and maintenance personnel quickly pinpoint issues.
Chargers and Power Distribution: Precise Scheduling Enables Full-Power Output
The DC charger employs the RUISU100030-DD charging module, offering a high power density of 45 W/in³. It supports hot-swapping and battery reverse‑current protection, while leveraging single‑phase active PFC (power factor correction) technology to enhance energy efficiency. The power distribution unit utilizes a rectangular switch‑scheduling scheme, dividing the 16 modules into two circuits, each capable of delivering up to 240 kW; together, the dual circuits provide a total output of 480 kW. When a charging terminal requests power, the system dynamically allocates idle modules to the corresponding terminal, ensuring efficient and stable charging operations.
Charging Terminal: Liquid-Cooling Technology Meets Diverse Needs
The system is equipped with 200–1000 VDC/600 A dual‑gun liquid‑cooled charging terminals and a 1200 A supercharging terminal, supporting both three‑level (NPC) and high‑power charging (HPC) modes, with each gun capable of delivering full power. The terminals feature the DDC‑RSA10‑S series controller, integrating billing and charging control functions, and enabling remote platform upgrades and data exchange. The premium version includes a 21.5‑inch color touchscreen and illuminated status indicators, offering both ease of operation and clear visual feedback; an optional camera can be added for facial‑recognition payments and operational monitoring, meeting the demands of commercial deployment.
Technological Value and Application Prospects
The mobile integrated energy storage and charging system, driven by core technological innovations, effectively addresses the challenge of recharging electric heavy-duty trucks in construction settings. Its modular trailer design adapts to a wide range of outdoor construction environments, while its 600A high‑current output enables an efficient “charge on loading/unloading” operating mode. Additionally, its dual‑platform compatibility—supporting both 400V and 800V systems—enhances the equipment’s versatility. Furthermore, the system can serve as an emergency rescue unit, swiftly reaching fault‑affected sites to provide power support, thereby expanding its application scope.
As the penetration rate of new‑energy heavy trucks continues to rise, this mobile charging‑and‑storage technology will play an increasingly significant role in sectors such as mining and infrastructure. Leveraging its technical advantages—on‑demand deployment, efficient energy replenishment, and environmental sustainability—it will help the construction‑equipment industry transition its energy mix and enhance operational efficiency, thereby providing crucial support for the further development of a new‑energy transportation system.
Click to consult! Get your personalized heavy-truck energy-replenishment solution.
If you’re struggling to find charging solutions for your heavy-duty trucks, simply scan the “Official Customer Service QR Code” below. Ruisu Intelligent Technology will tailor a customized charging solution based on your fleet size and local environmental conditions.
Ruisu Intelligence
Company website: www.gzruisu.com
Company Name: Guangzhou Ruisu Intelligent Technology Co., Ltd.
Company Service Hotline: 020-66260688 / 133-3288-5836
Company Address: No. 160, Tashan Avenue, Zengjiang Street, Zengcheng District, Guangzhou, Guangdong Province
#Megawatt Flash Charging Technology #Energy Storage in Oilfield Drilling Scenarios #NewEnergyChargingUpgrade #ZeroCarbonTransportation #Ruisu Intelligent Technology
Keywords:
Related News
Ruisu WeChat
Scan the code to follow the official account.
Contact Us
No. 160, Tashan Avenue, Zengjiang Street, Zengcheng District, Guangzhou City
©2026 Guangzhou Ruisu Intelligent Technology Co., Ltd. All Rights Reserved. | Website Development: China Enterprise Dynamics, Guangzhou