As more commercial EV fleets adopt DC fast chargers, the weight and volume of charging cables introduce operational challenges that can impact safety, maintenance costs and vehicle uptime.
Charged recently chatted with Eric Witkowski, Product Manager at Hubbell, to discuss an often-overlooked aspect of EV charging infrastructure: cable management. Hubbell’s Gleon Reel and related solutions aim to address these pain points with practical, industrial-grade tools.
Witkowski demonstrated the DWR Reel, a motorized overhead cable system designed for high-ceiling installations. It allows operators to drop the charging cable from above and retract it when not in use. This approach eliminates ground-level clutter, which reduces trip hazards and limits damage from weather, vehicles, or foot traffic. Especially in high-use environments like fleet depots, cable protection helps ensure charging ports stay functional and reduce wear on expensive components.
Another key challenge is the difference in cable handling requirements between Level 2 and Level 3 charging. Level 3 cables can weigh up to 60 pounds—significantly more than Level 2—making them harder to manage and more susceptible to damage if mishandled. Witkowski explained that Hubbell’s solutions like the Charge Base, a jib-and-crane system with a trolley and cable balancer, help operators move cables efficiently to different vehicle ports without dragging or bending the cable.
The discussion also covered how unplanned downtime can be costly for fleet operators. Without proper cable management, a single damaged cable or connector can take a charging station offline for days or weeks. This not only affects vehicle readiness but also introduces unexpected repair expenses and operational disruptions. Witkowski noted that uptime has always been a top priority for fleet managers, and small improvements in cable handling can have a meaningful impact.
The interview also introduced the Chance Instant Foundation, another innovation designed for rapid deployment of EV chargers. This system avoids the need for poured concrete, instead using a drill-in-place foundation that simplifies installation. For fleet operators scaling quickly or building temporary charging stations, this can reduce deployment time and complexity. Taken together, Hubbell’s portfolio reflects a practical approach to improving EV infrastructure reliability and operational safety.
Learn more at: https://www.hubbell.com/gleasonreel/en/solutions/ev-charging-cable-reels