igus launches e-tract overhead charging system for e-mobility

To meet the operational challenges of logistics centres, transshipment yards and bus depots, igus has developed the horizontal e-tract DC, a system that elevates the cables of high-power charging stations for electric trucks and heavy-duty vehicles. By keeping cables off the ground, the solution prevents vehicles from running over them or colliding with charging infrastructure, makes drivers' work easier, and reduces the risk of damage, theft and service interruptions. The system is also available in an alternating current (AC) version for electric cars in underground car parks.

Automation and ergonomics for high-power systems
The cables for ultra-high-power charging systems (Megawatt Charging System, MCS) require large-cross-section copper conductors and robust insulating layers, weighing up to 4 kg per metre. Connecting and disconnecting them several times a day can therefore involve significant physical effort. The horizontal e-tract DC system consists of a guide channel installed as a standalone unit or fixed to supports or hall structures above the height of the driver's cab. When the operator activates the mechanism, an integrated belt pushes the cable forward and slowly lowers the charging plug to the height needed to connect it to the vehicle. According to Marcello Mandelli, Country Manager of igus Italy, the system is less prone to failure than floor-mounted solutions and, thanks to the automatic lowering, significantly reduces the physical effort required from the operator.

Compact AC versions and theft protection
For multi-storey or underground car parks, where space for floor-mounted stations or wallboxes is often limited, igus offers an AC version with more compact guide channels, which can be installed directly above the parking spaces. The thinner, lighter cables lower automatically towards the vehicle at the push of a button. In both versions, the cables are automatically retracted and kept out of reach when not in use, making copper theft more difficult. The problem is significant: in 2025, EnBW, one of the main fast-charging network operators in Germany, recorded between 15 and 20 thefts per day, with estimated costs of between 5,000 and 8,000 euros per incident.

Additional Context:
This section explains general principles of ultra-high-power charging that are not included in the original press release.

Charging heavy vehicles in the megawatt range requires very high direct currents. According to Joule's law, the power dissipated as heat in a conductor is equal to the square of the current multiplied by the resistance (P = I² × R): doubling the current quadruples the heat generated. To limit heating, the cables must have a very low resistance, which requires large-cross-section copper conductors and robust insulation.

This is why ultra-high-power charging cables are much thicker and heavier than those for electric cars. Their weight makes repeated manual handling demanding and increases the interest of thieves in the copper they contain. Systems that bring the cable to vehicle height and retract it when not in use address both of these aspects.

Edited by an industrial journalist, Lekshman Ramdas, with AI assistance.

www.igus.com