Smart Load Management for Complex EV Charging Depots

The Challenge

‍

Bump operates high-demand EV charging hubs for logistics leaders like DHL, where uptime and precision are critical.
‍

At DHL’s depot in Lyon, the infrastructure includes nearly 80 charge points spread across multiple grid layers, sub-clusters, and power meters, all within limited grid capacity.
‍

This setup created four core challenges:

• Complex multi-layer grid infrastructure: Multiple meters and sub-distributions made centralized control difficult and inefficient

• Risk to logistics operations: Charging had to match strict fleet schedules, any disruption could impact deliveries

• Limited grid capacity for scaling: Adding more vehicles risked exceeding available power without costly upgrades

• Lack of real-time, granular control: Traditional cloud-based systems couldn’t manage site-level complexity fast enough
  ‍

In short, Bump needed a way to turn a constrained, fragmented energy system into a reliable and scalable charging operation.
‍

The solution
‍

Bump deployed FLEXECHARGE’s GATEWAY (local controller) combined with advanced Load Management to gain full control of the site.

‍

This setup enabled real-time, site-level intelligence and orchestration:
‍

• Real-time local control with GATEWAY: Charging decisions are made on-site, without relying on cloud latency

• Advanced multi-level load management: Energy is dynamically distributed across all chargers, meters, and grid layers

• Full integration of complex infrastructure: Chargers, meters, and sub-grids operate as one coordinated system

• Fleet-first charging logic: Vehicles are charged based on operational needs — ensuring readiness, not just energy efficiency
  ‍

This architecture transformed the depot into a fully synchronized charging ecosystem, capable of handling high complexity in real time.

‍

The impact

‍

With FLEXECHARGE, Bump turned one of its most complex sites into a high-performing, scalable EV charging operation:
‍

• Stable charging across ~80 charge points: Reliable performance even under grid constraints
• Maximum use of existing grid capacity: No need for costly infrastructure upgrades
• Operational continuity for DHL fleets: Vehicles are ready when needed, supporting logistics efficiency
• Proven scalability for complex depots: Demonstrates how multi-layer sites can be electrified successfully
• Future-ready infrastructure: Enables further expansion of fleet electrification