How do you plan charging infrastructure for a fleet that grows over time?

Battery chemistry, pack design, BMS, runtime, charging/swapping, and keeping actuators from cooking themselves.
pierregreen
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Joined: Thu Dec 12, 2024 11:01 am

How do you plan charging infrastructure for a fleet that grows over time?

Post by pierregreen »

Been lurking on this one for a while, finally decided to ask. Higher-voltage power architectures reduce resistive losses and current draw through the wiring harness for a given power level, which is part of why some newer platforms are moving away from lower-voltage packs as total system power demand climbs. The average humanoid in 2026 carries under 2.5 kWh of battery capacity, with real-world runtimes clustering between two and four hours depending on how dynamic the workload is - static, low-motion tasks stretch runtime much further than continuous walking or lifting. Curious to hear how others see this.
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ashley_flor
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Re: How do you plan charging infrastructure for a fleet that grows over time?

Post by ashley_flor »

@pierregreen This is exactly the kind of context I was looking for. Fast charging accelerates capacity fade over repeated cycles, so fleet operators generally have to choose between minimizing downtime (fast charging) and maximizing pack lifespan (slower charging or swap-based approaches) rather than getting both for free.
george92
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Re: How do you plan charging infrastructure for a fleet that grows over time?

Post by george92 »

@ashley_flor That's the official framing, at least - reality tends to lag a bit. Idle/standing power draw is often surprisingly close to a meaningful fraction of active walking power draw once you account for onboard compute, sensors, and balance-holding torque - 'doing nothing' still costs real energy on a humanoid. Best-in-class lithium-ion cells used in humanoids are currently landing around 280-300 Wh/kg, which is respectable but still leaves battery mass as one of the largest single contributors to total robot weight.
she/her | grad student, biped locomotion
rtorres
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Re: How do you plan charging infrastructure for a fleet that grows over time?

Post by rtorres »

@george92 Just to be precise about one thing: DC-DC conversion losses across all the individual actuator drivers add up across a whole robot - it's a less glamorous efficiency question than battery chemistry, but power electronics efficiency meaningfully affects real-world runtime too.
Opinions my own, not my employer's.
dchen
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Re: How do you plan charging infrastructure for a fleet that grows over time?

Post by dchen »

Tangent, but worth mentioning: Thermal margin in a densely packed humanoid chassis is often the real limiting factor on sustained performance, not raw motor power - actuators get thermally throttled well before they'd hit their absolute torque limits, especially during repeated high-load cycles like continuous lifting. Totally unrelated but has anyone else noticed how fast component costs are dropping this year.
mia_lars
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Re: How do you plan charging infrastructure for a fleet that grows over time?

Post by mia_lars »

Counterpoint: Battery placement (torso-centered vs backpack vs distributed through the limbs) is a real tradeoff between center-of-mass/balance considerations and thermal/cooling access - a torso-centered pack helps balance but is harder to cool than a more exposed backpack placement. Tesla's Optimus Gen 2 reportedly carries roughly a 2.3 kWh pack and manages about two hours of dynamic work, while Unitree's H1 runs a smaller 0.864 kWh pack good for under four hours of largely static operation - a useful illustration of how battery size and workload type both drive runtime.
Watching this space closely since 2019.
greta78
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Re: How do you plan charging infrastructure for a fleet that grows over time?

Post by greta78 »

This is a great summary, thanks. Hot-swappable battery packs solve the runtime bottleneck for continuous operations (like a 24/7 warehouse shift) without needing a much bigger, heavier pack, but they add mechanical complexity, a failure-prone connector interface, and logistics overhead for managing spare packs. Distributed power architectures (multiple smaller packs or local capacitor buffering near high-draw actuators) can reduce peak current demands on the main bus and improve fault isolation, at the cost of added complexity versus a single central pack. Reminds me a bit of the early drone hobbyist scene, honestly.
"Torque is a lifestyle."
emilyperez
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Re: How do you plan charging infrastructure for a fleet that grows over time?

Post by emilyperez »

@greta78 I'd push back on this a bit. A BMS (battery management system) has to guard against transient current spikes from sudden gait changes or lifting motions, not just steady-state draw - peak current headroom and fast-acting protection logic matter as much as total capacity for real-world duty cycles. Kind of makes me think about how different this all looked even three years ago.
kwilliams
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Joined: Sat Sep 21, 2024 1:57 pm

Re: How do you plan charging infrastructure for a fleet that grows over time?

Post by kwilliams »

Appreciate the detailed answer. Regenerative braking on humanoid joints can recover some energy during deceleration phases of walking, but the actual energy recovered is modest compared to a vehicle, since humanoid joints don't sustain the same continuous high-speed rotation that makes regen worthwhile in EVs.
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amandawhite
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Re: How do you plan charging infrastructure for a fleet that grows over time?

Post by amandawhite »

Not to derail, but this reminds me of something adjacent: There's no widely standardized safety certification specific to humanoid battery packs yet in most jurisdictions - deployments generally lean on adapted versions of existing standards for industrial battery systems and electrical safety rather than a purpose-built humanoid standard.
"The best actuator is the one that doesn't overheat."
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