Smart Load Management for Complex EV Charging Depots

The Challenge

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Bump operates high-demand EV charging hubs for logistics leaders like DHL, where uptime and precision are critical.
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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.
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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
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In short, Bump needed a way to turn a constrained, fragmented energy system into a reliable and scalable charging operation.
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The solution
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Bump deployed FLEXECHARGE’s GATEWAY (local controller) combined with advanced Load Management to gain full control of the site.

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This setup enabled real-time, site-level intelligence and orchestration:
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• 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
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This architecture transformed the depot into a fully synchronized charging ecosystem, capable of handling high complexity in real time.

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The impact

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