Articles

Rethinking the Charge. How Overhead Technology Transforms EV Charging

Westfalia Technologies Introduces WEPLUG®, Leveraging Decades of Automation Expertise for Reliable, Space-Saving EV Charging

The Electric Vehicle (EV) revolution is not coming: it’s here. With projections showing EVs could make up over 50% of US passenger vehicle sales by 2030 (BloombergNEF June 12^th, 2024), the demand for convenient, reliable charging infrastructure is exploding. However, simply flooding the market with chargers is not the answer, especially in space-constrained environments like dense urban centers, multi-unit dwellings and large parking structures.

For architects and developers designing the next generation of urban spaces, the integration of efficient EV charging infrastructure with automated parking creates a powerful sustainability synergy. Conventional approaches often force a choice between parking density and charging accessibility. However, by combining Westfalia’s automated parking expertise with WEPLUG’s overhead charging innovation, projects can achieve both simultaneously.

The environmental impact is substantial: automated parking systems already reduce carbon emissions by cutting vehicle idling and circulation within garages. When paired with WEPLUG’s high-density charging capabilities, these sustainable parking solutions enable more comprehensive electrification without sacrificing valuable urban space. For developers facing stringent sustainability requirements and increasing EV adoption rates, this integrated approach offers a competitive advantage in attracting forward-thinking tenants and residents while meeting increasingly stringent building codes requiring EV readiness. This revolution in parking goes beyond simple space efficiency, it represents a fundamental reimagining of how urban infrastructure can support the clean energy transition while maximizing property value and enhancing user experience.

Current Challenges with Structured EV Charging

Integrating EV charging into automated parking systems and conventional covered garages presents several significant challenges for developers and operators. Space inefficiency becomes immediately apparent when dedicating valuable floor or wall areas to chargers in every potential EV spot, reducing overall capacity or necessitating larger, more expensive builds. The infrastructure costs compound this problem, as running individual high-power circuits to numerous parking spots creates expensive and complex electrical requirements that strain building capacity. Cable management introduces added complications with unsightly dangling cables creating potential trip hazards while remaining prone to damage. Reliability concerns emerge when considering robotic arms handling standard charging plugs, which must navigate varying port locations and alignments, even in covered areas where environmental factors and general wear-and-tear from delicate maneuvering pose significant operational risks. Finally, scalability issues arise when facilities try to add charging capacity incrementally, often requiring substantial additional infrastructure work that disrupts operations and increases costs. WEPLUG® addresses these challenges through its innovative overhead gantry system that efficiently services multiple vehicles without these traditional limitations.

Charging from a New Perspective – Overhead

Recognizing these challenges, we introduced WEPLUG®. This is not just another charger, it is a patented, overhead automated EV charging system designed specifically for the demands of modern parking environments.

Instead of placing a charger at every spot or using complex robotics for plugging, WEPLUG® uses a robust overhead gantry system – technology Westfalia has perfected over decades in demanding industrial applications. This gantry intelligently moves a powerful 50kW DC fast charger to the parked vehicle needing a charge.

Why is WEPLUG® a Significant Change?

WEPLUG® addresses the core pain points of structured EV charging through intelligent design:

• Maximum Space Efficiency: By moving the charger overhead, WEPLUG® frees up valuable floor and wall space around parking spots. This is critical in high-density automated parking systems and valuable in any covered garage.

• Drastically Simplified Infrastructure: The most significant advantage, WEPLUG® typically requires only ONE main utility connection for the gantry system to serve multiple parking spots. This dramatically reduces electrical infrastructure costs, complexity, and installation time compared to per-spot solutions.
• Enhanced Reliability & Reduced Failure Points: We have learned from decades of automation: keep it robust. WEPLUG® avoids the complexities of robotic plug insertion. The system relies on the user making a simple, secure connection with a dedicated adapter upon parking. The gantry then handles the automated delivery of the charger to this reliable connection point, minimizing delicate maneuvers prone to failure. This focus on reliability is paramount.
• Flexible & Scalable: The gantry can be designed to serve a designated zone of parking spots, offering scalability. Need more capacity? It is often more manageable to optimize gantry programming or add another system than to rewire dozens of individual spots.
• Fast, Efficient Charging: Using a 50kW DC fast charger, WEPLUG® can typically bring most EV batteries to 80% charge in about an hour or less, significantly faster than Level 2 chargers and meeting the needs of most drivers during dwell times (e.g., overnight residential, workday charging).

Leveraging Westfalia’s Proven Automation Pedigree

The innovation of WEPLUG® is not accidental. It stems directly from Westfalia Technologies’ core strengths:

• Automated Parking Expertise: Westfalia is already a trusted name in automated parking systems, understanding the unique spatial and operational requirements. WEPLUG® is a natural extension of this expertise.

• Decades of ASRS Leadership: Westfalia has been designing, manufacturing, and installing mission-critical automated storage and retrieval systems since 1992. We understand the demands of 24/7 operation, heavy loads, and precision movement in complex environments.

• Vertical Integration: Westfalia controls every aspect from design to service, manufacturing most solutions in-house at our US facilities. Our 100% American designs, programming, and support are developed specifically for the US market, while our strategic partnership with Westfalia Technologies GmbH & Co. KG in Germany complements our production capabilities, offering flexible manufacturing options across both Americas and Europe. This comprehensive approach delivers unmatched quality and responsiveness compared to component assemblers.

• Proven Reliability: Our systems operate in demanding logistics, distribution, and manufacturing facilities where downtime is not an option. We bring this same commitment to mission-critical reliability to the parking and charging experience. For developers, facility managers, and fleet operators, ensuring vehicles are parked efficiently and charged reliably is mission-critical.

Beyond the Automated Garage: Applications for WEPLUG®

While seamlessly integrating with Westfalia’s own automated parking systems, WEPLUG’s advantages make it ideal for a range of covered conventional parking applications:

• Multi-Unit Dwellings: Provide reliable, space-saving charging amenities for residents without overhauling garage infrastructure.
• Corporate Campuses: Offer premium, hassle-free charging for employees.
• Airport Parking: Ensure travelers’ vehicles are charged upon return, managing power efficiently across large garage zones.
• Fleet Depots: Guarantee electric fleet vehicles are reliably charged and ready for operation, a critical step for logistics and delivery services.

The Future is Integrated, Automated, and Reliably Charged

The transition to electric mobility requires infrastructure that is as smart and efficient as the vehicles themselves. Simply adding more plugs is not innovation. WEPLUG® represents a fundamental shift, addressing the core challenges of space, cost, and reliability in structured parking environments.

By using proven overhead automation technology and a deep understanding of mission-critical systems, Westfalia is providing architects, developers, and operators with a truly forward-thinking solution.

WEPLUG® Charging forward.