Category: Project Case Study | Infrastructure How Our Box-Type Substation Powers a Thriving Charging Station – And Why We’re Reinforcing for the Next Decade
A Living Laboratory at Our Factory Gate
Five years ago, Sichuan Zhongxin General Electric Energy Co., Ltd partnered with a specialized charging equipment manufacturer to build an electric vehicle charging station on the open ground to the left of our factory entrance. What began as a collaborative project exploring the emerging EV infrastructure market has evolved into both a reliable revenue source and a real-world validation platform for our electrical equipment under demanding conditions.
This charging station serves as a working demonstration of our box-type substation technology, operates 24/7 supporting heavy-duty electric trucks from neighboring industrial facilities, and generates approximately $10,000 USD in monthly profit share for our company after partnership distribution. More importantly, it provides five years of performance data that we can confidently share with customers considering similar projects.
Project Origins: A Partnership Decision and Its Evolution
When our charging equipment partner first approached us five years ago with a proposal to jointly manufacture charging pile systems, we faced a strategic decision. At that time, the electric vehicle charging infrastructure market in China was experiencing rapid growth, and our partner saw an opportunity to expand from equipment supply into manufacturing.
After careful consideration of our core competencies and market positioning, we chose not to enter charging pile manufacturing directly – a decision that, in retrospect, meant missing what became a significant market expansion window. However, this choice allowed us to maintain focus on our primary strengths: power transformation and distribution equipment.
The relationship with our charging equipment partner evolved into something equally valuable. Through five years of close collaboration on this operational project, we’ve built deep mutual trust and understanding of each other’s technical capabilities and service standards. Today, we leverage this relationship to support customers who need turnkey charging station solutions: we provide the critical power infrastructure (substations, switchgear, power distribution), our partner supplies proven charging equipment, and we deliver comprehensive technical support and after-sales service for the complete system.
Technical Configuration and Performance
Power Infrastructure
The charging station connects directly to the State Grid’s 10kV distribution line. Power transformation and distribution is handled by a box-type substation manufactured at our facility specifically for this project – effectively serving as both operational equipment and a long-term product demonstration.
Charging Capacity
The station features:
- 11 charging units with 22 charging guns
- Capacity to support heavy-duty electric trucks
- Equipment supplied by our trusted charging technology partner
- 24/7 operational availability
Real-World Testing: Heavy-Duty Demands
Our charging station’s location in an industrial zone provides the ultimate stress test for electrical equipment. Immediately adjacent to our facility are two large concrete precast component factories. Their fleets of heavy-duty electric trucks rely heavily on our charging station, creating usage patterns far more demanding than typical urban charging scenarios.
These are not light passenger vehicles making occasional stops. We serve commercial electric trucks carrying multi-ton concrete loads, requiring rapid high-capacity charging to maintain operational schedules, and returning multiple times daily. Over five years, our box-type substation and the charging infrastructure have reliably supported this intensive use without significant electrical failures.
This real-world performance data is invaluable when discussing charging station projects with potential customers. We can speak from direct operational experience about power quality stability, equipment durability under heavy load cycles, and the long-term reliability of properly specified electrical infrastructure.
The Unintended Consequence: Ground Surface Degradation
While our electrical equipment proved remarkably durable, the original concrete ground surface did not fare as well under five years of heavy truck traffic. Vehicles weighing tens of tons, maneuvering repeatedly into charging positions and idling during extended charging sessions, gradually cracked and damaged the concrete foundation.
This presented both a practical problem and an opportunity. The deteriorating surface posed safety concerns and hindered efficient station operations. However, the Spring Festival holiday period – when our factory operations pause and charging demand decreases – offered an ideal window for comprehensive ground renovation without disrupting customers or production.
Spring Festival Infrastructure Upgrade: Engineered for Durability
During the Spring Festival holiday period, while most team members enjoy well-deserved time with their families, our infrastructure maintenance crew executed a carefully planned ground surface reconstruction project. The goal: create a foundation capable of withstanding another decade of heavy-duty truck traffic.
Engineering Approach: Heavy Reinforcement
Learning from five years of operational stress, this renovation employs significantly more robust construction techniques. The key difference: dense networks of thick steel reinforcement bars (rebar) embedded throughout the concrete foundation. This heavy reinforcement distributes the concentrated loads from truck wheels across a much larger area, dramatically improving structural integrity and crack resistance.
Three-Day Execution Timeline
The renovation followed a compressed but methodical schedule:
Day 1: Removal of damaged concrete surface. Heavy equipment broke up and cleared the fractured original foundation, preparing a clean base for reconstruction.
Day 2: Steel reinforcement installation. Workers positioned and tied the dense rebar grid according to structural engineering specifications, creating a robust framework throughout the entire charging station surface area.
Day 3: Concrete pouring and finishing. Using pumper trucks to deliver and distribute concrete efficiently across the large surface area, the team completed the pour and began the curing process.
Charging Station Location and Facility Integration
The charging station’s position at our factory entrance is strategic for both operational and demonstration purposes. Customers visiting our facility immediately see active electrical infrastructure in daily use – our box-type substation supporting real-world heavy-duty charging applications right at the gate.
This visible integration into our daily operations provides immediate credibility in customer discussions. When we discuss charging station projects, customers can see that we’re not just selling equipment – we operate it ourselves, maintain it continuously, and rely on its performance for our own revenue generation.
A Profitable Partnership Model
The charging station operates under a clear partnership structure that has proven mutually beneficial over five years:
- Sichuan Zhongxin provides: The land, the power infrastructure (box-type substation and connections), ongoing site maintenance, and local operational oversight
- Our charging equipment partner provides: Charging pile hardware, charging management software/payment systems, technical support for charging equipment, and customer service for charging users
- Revenue sharing: Operating income is divided according to partnership agreement, with Sichuan Zhongxin receiving approximately $10,000 USD monthly as our profit share
This financial performance over five years validates both the technical reliability of our equipment and the business viability of properly managed charging infrastructure in industrial locations. The station’s consistent profitability demonstrates that heavy-duty commercial charging – when matched with appropriate power infrastructure and positioned near high-demand users – can deliver attractive returns on investment.
What This Means for Potential Customers
For companies and organizations considering electric vehicle charging station projects, our five-year operational experience offers several valuable insights:
Proven Equipment Performance
Our box-type substation has operated continuously in a demanding application for five years without electrical failures. This is not laboratory testing or theoretical specifications – it’s real-world proof of reliability under heavy commercial use.
Turnkey Solution Capability
While we chose not to manufacture charging piles ourselves, we’ve built a trusted relationship with a specialist partner. We can deliver complete charging station solutions combining:
- Our expertise and products: Power infrastructure design, box-type substations, switchgear, power distribution, grid connection engineering
- Our partner’s expertise and products: Charging pile equipment proven over five years in our own facility
- Comprehensive support: Technical consultation, system integration, installation guidance, after-sales service
Honest Assessment Based on Experience
Having operated a charging station for five years, we understand the real challenges – not just the technical specifications. We can discuss power quality requirements, usage pattern predictions, maintenance considerations, and realistic revenue expectations based on actual data rather than marketing projections.
Built to Last: Infrastructure for the Electric Future
The Spring Festival ground renovation project reflects our commitment to long-term thinking. Rather than simply repairing the damaged surface with minimal intervention, we invested in heavy reinforcement designed to support another decade of intensive use. This approach – building infrastructure to last – mirrors our philosophy in power equipment manufacturing.
As the Spring Festival holiday concludes and operations resume, truck drivers returning to charge their vehicles will find a renewed facility ready to serve them reliably. The heavy reinforcement hidden beneath the fresh concrete surface represents not just structural engineering, but a commitment to sustained service and operational excellence.
For Sichuan Zhongxin, this charging station will continue serving multiple purposes: generating steady income, demonstrating our equipment capabilities, validating our design choices, and enabling us to offer customers genuine operational insights when they consider their own charging infrastructure projects.
Lessons from Five Years of Operation
This charging station project has taught us that:
- Well-designed electrical infrastructure can perform reliably in demanding commercial applications for many years
- Partnerships built on complementary strengths can create value even when initial opportunities are declined
- Real operational experience is far more valuable than theoretical knowledge when advising customers
- Infrastructure maintenance and upgrades, timed strategically, can extend asset life significantly
- The electric vehicle transition creates opportunities for power equipment manufacturers who understand both the technology and the business models
As we continue operating this charging station and supporting customers developing their own projects, we carry forward five years of authentic experience – equipment performance data, business model validation, and practical problem-solving insights that can only come from real-world operations.
Interested in Charging Station Projects?
Sichuan Zhongxin General Electric Energy can support your electric vehicle charging infrastructure development with:
- Power infrastructure design and engineering (grid connection, substations, distribution)
- Box-type substations specifically configured for charging applications
- Coordination with proven charging equipment suppliers
- Technical support based on five years of operational experience
Contact us to discuss how our experience can help make your charging station project successful.
Related Articles:
Recent Company Updates and Project Milestones
2025 Annual Marketing and Sales Conference
2026 Chinese New Year Annual Gala
