How does equipment duty cycle analysis inform electric vehicle selection for terminals?

Equipment duty cycle analysis examines how terminal equipment operates throughout its working period, tracking operational hours, idle time, load variations, and energy consumption patterns. This analysis directly informs container terminal electrification decisions by determining battery capacity requirements, charging infrastructure specifications, and operational viability. Understanding these usage patterns helps terminal operators select electric vehicles that match actual operational demands whilst ensuring reliable performance.

What is equipment duty cycle analysis and why does it matter for terminal electrification?

Duty cycle analysis documents the complete operational profile of terminal equipment, measuring working hours, power demands during operation, idle periods, and the intensity of use across shifts. For terminals considering electrification, this analysis reveals whether electric alternatives can sustain the required operational tempo without compromising productivity.

The analysis matters because battery-powered equipment requires fundamentally different operational planning compared to diesel alternatives. Electric vehicles need charging windows, and battery capacity must accommodate both active operation and the energy demands of peak workload periods. Without accurate duty cycle data, terminals risk selecting electric equipment with insufficient range, inadequate power output, or incompatible charging requirements.

This assessment also determines total cost of ownership for electric fleets. Battery sizing affects capital expenditure, whilst charging infrastructure requirements influence both installation costs and ongoing operational patterns. Research indicates that battery-powered fleets may require 10-25 per cent additional equipment to maintain operational capacity during charging cycles, making duty cycle analysis important for realistic financial planning.

How do you actually measure and analyze equipment duty cycles at terminals?

Measuring duty cycles requires collecting operational data over sufficient duration to capture representative patterns. Telematics systems installed on equipment provide continuous monitoring of engine hours, power consumption, movement patterns, and idle periods. These systems generate detailed records showing when equipment operates, at what intensity, and for how long.

Operator logs and terminal operating system data supplement telematics information, providing context about shift patterns, vessel call sizes, and workload variations. The key metrics include:

  • Operating hours per shift – total active time during each work period
  • Peak load periods – when equipment experiences maximum demand
  • Idle time percentages – proportion of time equipment remains stationary
  • Energy consumption patterns – power usage across different operational phases
  • Frequency of operational cycles – repetition rates of work sequences

For container terminals, this means tracking how many container moves occur, the distance travelled between operations, and the duration of inactive periods.

Analysis duration should span at least several months to account for seasonal variations in terminal operations. Understanding these patterns requires recognizing that vessel call patterns, cargo volumes, and operational intensity fluctuate throughout the year. A comprehensive assessment captures these variations, ensuring electric vehicle selection accommodates both typical operations and peak demand periods. Simulation analysis tools can model this collected data against different equipment specifications and charging strategies to predict performance under various scenarios.

What factors should you consider when matching electric vehicles to duty cycle data?

When evaluating electric vehicle suitability for terminal operations, several critical factors determine whether the equipment will meet operational requirements:

Factor Considerations Impact on Operations
Battery Capacity Energy storage for continuous operation between charges; accounts for active handling and movement power Determines operational duration before recharging required
Charging Windows Alignment with shift patterns; opportunity charging vs. dedicated charging periods Affects productivity and fleet sizing requirements
Power Output Sufficient power for maximum load conditions; lifting capacity and travel speeds Ensures performance during peak operational demands
Range Requirements Terminal layout and distances between operational areas Influences battery size and charging frequency
Infrastructure Compatibility Grid capacity for simultaneous charging; power demand at shift changes Determines electrical infrastructure investment needed

Battery capacity represents the primary consideration when matching electric vehicles to duty cycle requirements. The analysis must show whether available battery technology provides sufficient energy storage for continuous operation between charging opportunities. This calculation accounts for both the energy consumed during active container handling and the power required for movement between operational locations.

Charging window availability determines whether the operational schedule accommodates battery replenishment. Terminal operations typically follow shift patterns, and charging strategies must align with these schedules without disrupting productivity. Some operations suit opportunity charging during brief operational pauses, whilst others require dedicated charging periods between shifts. The duty cycle data reveals which approach fits the operational reality, addressing one of the key industry challenges facing terminal operators today.

How we help with equipment duty cycle analysis and electric vehicle selection

We support terminals through the electrification decision process using detailed simulation analysis that models electric vehicle performance under realistic operational conditions. Our approach combines duty cycle assessment with validated simulation tools designed specifically for terminal operations, providing quantitative insights into equipment requirements and infrastructure specifications.

Our services include:

  • Detailed simulation analysis for electric vehicles – testing different equipment types, fleet sizes, and charging strategies against actual operational patterns
  • Tailored simulation models – accounting for terminal-specific layouts, workload patterns, and operational constraints
  • Financial evaluation using validated modelling tools – assessing the business case for electrification scenarios
  • Charging infrastructure analysis – determining the number of charging points required and power demand profiles throughout operational periods
  • Phased implementation planning – identifying optimal transition pathways from diesel to electric equipment

Our simulation models are validated against data from live terminal operations, and our team of modelling experts at Portwise Consultancy brings extensive experience in terminal design and automation. This combination enables us to provide realistic assessments of how electric equipment will perform in your specific operational context, helping you make informed decisions about container terminal electrification investments.

If you’re interested in learning more, reach out to our team of experts today.

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