Building the charging infrastructure of the future together

Text Beatrice Svala, Digital Marketing Communicator, Elpress
Photo: Eviny & Install

When the energy and technology company Eviny was setting up a new public fast-charging station in Töcksfors in Sweden, the collaboration between Eviny, Install, Amokabel AB and Elpress group proved to be a crucial part of the end result. By combining expertise in charging infrastructure, installation, cabling technology and tried-and-tested connection solutions, a facility was created where the focus went beyond individual components. The aim was to build a system that would function effectively in the long term – a system designed for high power, high availability and the future demands on charging infrastructure.

Among those behind the project is Jacob Andersson, Project Manager for Sweden at Bilkraft Sverige AB, Eviny A/S, who led the work on Eviny’s behalf.

From a component-based approach to a system-based approach

In many projects, electrical connections are still treated as a matter concerning individual components.

But in reality, the end result is influenced by the entire chain:

• Cable type and conductor structure
• Material combinations
• Crimping method
• Tools
• Installation
• Environment and stress over time

If one part of the chain is not adapted to the rest, risks arise that are often not immediately apparent – but only become evident after years of operation.

This is why the collaboration between Eviny, Install, Amokabel and Elpress was so crucial to the Töcksfors project.

Eviny was responsible for the overall system choices and the requirements regarding the facility’s performance and future-proofing. Install handled the installation and detailed design based on the actual conditions at the site. Amokabel contributed the flexible AXQ Flex Class 5 cable, and Elpress provided the tried-and-tested DUAL5 concept for flexible aluminium conductors.

No part of the project was developed in isolation from the others.

A collaborative effort on the high-power solutions of the future

In Töcksfors, 12 public fast-charging points were installed, with a power output of up to 400 kW and support for both 400V and 800V battery systems.

When the decision was made to use flexible aluminium cable, new technical requirements also arose. Flexible aluminium conductors behave differently to traditional conductors. The conductors are more mechanically sensitive, whilst aluminium’s natural oxide layer places high demands on the crimping process itself. A solution that works for one type of cable may not work optimally for another.

It was also at this point that the dialogue between Amokabel, Elpress and Eviny gained momentum.

For Amokabel, the project focused from the outset on finding a more installation-friendly solution for the high-power installations of the future.

Dan Johansson also believes that the value of the project lay in creating a truly comprehensive solution in collaboration with other stakeholders.

“Together with Elpress cable lugs and the DUAL5 system, customers can benefit from a comprehensive solution for cabling and terminations. With our new flexible Class 5 aluminium cables, installations can be carried out much more smoothly in confined spaces where traditional Class 2 cable is often difficult to work with. This project clearly demonstrates the value of more installation-friendly and modern cabling solutions.”

When the installation becomes a reality

For Install, the difference became clear out on the installation site itself.

In Töcksfors, the cable routing had to be adapted to existing infrastructure such as water, ventilation, drainage and sprinkler systems. At the same time, space was limited and several cable runs had to be managed in different directions.

– “The cable is definitely much easier to bend and handle where space is limited. It’s almost like working with copper cable, but considerably lighter,” says Martin Gulle at Install.

He also describes how the choice of Class 5 aluminum affected both the working environment and the end result.

“For us, using Class 5 cable in this installation made things incredibly easier. We saved time and enjoyed a better working environment, and as a bonus, the installation also looked considerably neater than we could have achieved with traditional Class 2 aluminum cable.”

At the same time, he emphasises the importance of the cable, connectors and tools working together as a verified system.

The connections in the project were based on the Elpress DUAL5 concept for flexible aluminum conductors, together with bimetallic connections for the transition between the aluminum cable and the copper connections in the charging equipment.

Collaboration that reduces uncertainty in the field

Martin Gulle believes that collaboration between the installer and the manufacturer also plays a major role when new solutions are to be implemented in practice.

“We appreciate it when contact with the manufacturer is straightforward and personal, so that we can quickly get answers to questions and help with choosing materials and tools. The first time we worked with Class 5 cable, we contacted Sune Dahlberg at Elpress, who helped us with both material selection and crimping equipment. He even came out to visit us on site, which was hugely appreciated.”

The next step for the industry is collaboration

Developments in charging infrastructure today also reflect a broader trend within the energy transition.

As the scale of operations increases and systems become more complex, it is no longer sufficient to optimise each component in isolation. Instead, the industry is moving towards closer collaboration between clients, installers and manufacturers to ensure long-term functionality, operational reliability and scalability.

Not to make the projects more advanced, but to reduce uncertainty over time.

The Töcksfors project demonstrates what happens when the entire supply chain works together towards the same goal: a charging facility built for genuine long-term sustainability – where quality lies not in any single product, but in the interplay between all the parts.

Case author: Beatrice Svala – Digital Communicator Elpress.