Urgent need for action for all stakeholders

The EU Cybersecurity Strategy, published in December 2020, focuses on resilience and attack blocking for major manufacturing companies. The strategy aims to implement security by design in products and systems, addressing the increasing attack area for cyberattacks and the increasing professionalism of attackers. Cyber security focuses on securing a company’s value creation and individual security objectives, including protecting know-how and complying with legal regulations. Significantly, the EU is now extending legal requirements for cybersecurity to include more companies.

Implementation in the automation sector

Based on ISO 27001/2, the information security management system (ISMS) in IT is being extended to operational technology (OT). Measures in the IACS environment can be applied by incorporating organizational and technical criteria, as part of this expansion. These measures include network configuration, data protection, user authentication, monitoring, device security hardening, and system management. The IEC 62443 series of standards addresses specific measures for the IACS environment, covering components, systems, operators, and service providers. The comprehensive security-by-design approach, known as the “defense-in-depth” concept, makes access more difficult for attackers.

Upvaluation of regulations through NIS 2

The EU’s NIS 2 directive, mandating cybersecurity measures for public and private entities, is changing the landscape. Specifically, it applies to companies with over 50 employees and more than 10 million euros in sales, focusing on essential and important facilities. Commencing from January 16, 2023, this directive must be transferred into national law by October 18, 2024. However, implementing security-by-design in products is challenging, and the EU has introduced the Cyber Resilience Act (CRA) to address this issue.

Development of security-by-design products in accordance with the Cyber Resilience Act

The Cyber Resilience Act (CRA) mandates manufacturers to create security-by-design products, ensuring they receive a CE mark if they comply with regulations. Minimum security measures must be demonstrated through conformity tests or manufacturers themselves using a harmonized standard. The CRA includes access protection, confidentiality protection, integrity, availability, and a secure delivery state. It also includes vulnerability management and regulations for manufacturers to provide security updates. The draft text of the CRA is in trialogue, expected to become EU law in 2024. To meet vulnerability management requirements, products must have a standardized Software Bill of Material and known vulnerabilities must be available in a standardized digital format.

Consideration of security in the new Machinery Directive

The Machinery Directive 2006/42/EC mandates machines to be equipped with functional safety technology, ensuring the protection of people and the environment from injuries or contamination. However, this standard requires updates due to new technologies and product safety regulations. Looking ahead, the Machinery Directive 2023/1230, set to be published by mid-2023, combines functional safety with cybersecurity.

360-degree security based on IEC 62443

Phoenix Contact, a German company, has implemented IEC 62443 since 2017. In this time frame, it has focused on a 360-degree security concept throughout its products and solutions. The company follows a secure development process, ensuring security-by-design and defense-in-depth. Additionally, It actively monitors vulnerabilities and provides regular security updates. Moreover, the company’s secure products comply with IEC 62443-4-1 and IEC 62443-4-2, including denial-of-service protection, user management, and data confidentiality. Furthermore, the company’s security services are certified by IEC 62443-2-4. The Phoenix Contact Security Team has developed templates for various solutions and markets, and the Product Security Incidence Response Team (PSIRT) manages security issues. Importantly, all certifications are monitored by TÜV Süd through annual audits.

Learn more about Industrial security.

Who still needs fossil fuels?!

Solar panels on trackers and roofs, on the facade, and on the sidewalks

Storage system as a battery booster for e-vehicle fast charging

Energy management system for evaluating energy flows

Sustainability even with the construction and cooling materials

The transformer station houses medium and low-voltage switchgear with transformers, disconnectors, and fuses. Sustainability was prioritized, using air instead of SF6 as an insulating medium and biodegradable ester fluid for cooling. Notably, carbon concrete was used instead of reinforced concrete. which led to a reduction in wall thickness by around one-third. Greenery on the facades and roof contributes to microclimate and small animal habitats. Looking ahead, future transformer stations will be located in cities for better air quality and cooling.

Creating awareness of the technical possibilities

Phoenix Contact is implementing an electrical energy management system using PLCnext Technology control technology to ensure reliable power supply to park devices. The system integrates park devices like inverters, storage systems, and charging stations into the system. Allowing data and values to be accessible. With a broader perspective, All Electric Society Park aims to raise awareness about the company’s future vision and technical capabilities, showcasing real applications and educational presentations. The park opened to the public on September 1, 2023.

Learn more about All Electric Society.

Innovative inner workings ensure the safety of DC connectors.

Into the future with direct current

Requirements on DC connectors

ArcZero tames the arc

Learn more about the DC connector.

The use of battery energy storage systems in power-to-X applications

The All Electric Society concept describes a future where renewable energy is the primary source of electricity worldwide, affordable, and abundant. Energy storage technologies, such as power-to-X and battery systems, are crucial for this vision, with the greatest potential in battery energy storage systems and green hydrogen production.

Power-to-X as an energy storage technology

Hydrogen is stored in renewable energy through electrolysis, breaking down water into hydrogen and oxygen. This gas is compressed and stored in tanks. When electrical energy is needed, hydrogen reacts with air in fuel cells to form water, We refer to this process chain as power-to-X technology.  The term generally refers to the conversion of surplus renewable energy into other energy carriers.

Battery energy storage systems

Battery storage efficiently stores electrical energy through chemical conversion in galvanic elements, allowing current to flow through electrodes connected via an electrical load.

Short and long-term storage

Battery storage differs significantly from power-to-X processes, as batteries require large, expensive batteries with precious materials. Unlike hydrogen storage, which is less expensive and has a higher energy density, power-to-X technologies have lower conversion efficiency due to waste heat generation. However, battery storage has over 90% efficiency, making it suitable for shorter storage periods, such as hours or days. This makes battery energy storage more economically viable for long-term storage.

In combination lies strength

The hydrogen process and battery differ in inertia, with batteries storing energy quickly and electrolyzers and fuel cells requiring power proportional to reactor size. Both operate at maximum efficiency within a small process window, avoiding major fluctuations. Combining these technologies can provide hybrid solutions for stationary or quasi-stationary electricity generation, covering consumer base load and battery for short-term load fluctuations. Electrical connection technology ensures efficiency and reliability.

The role of electrical connection technology

Electrical connection technology is crucial for efficiency and reliability in batteries, electrolyzers, and fuel cells. It requires power, signal, and data connections, with analog signals controlling sensors and digital communication systems.

Examples of faults in the connection technology

Inconspicuous components like power wiring, signal connections, and data connections are crucial for system safety. Classic screw connections can loose in unfavorable conditions, leading to increased contact resistance and heat loss. Signal connections, such as sensor cables, can be soldered directly, resulting in cold solder points and incorrect temperature measurements being too low. Data connections, often created using patch cables, can also cause faults during transmission, leading to system malfunctions and hardware damage.

Recommendations for selecting connection technology

To avoid financial losses, system operators should use plug-in connectors for power connections when installation conditions cannot be guaranteed. Innovative connection technologies like insulation displacement connections offer convenience and reliability. For data connections, ambient conditions dictate requirements, with IP-protected data connectors ideal for high pollution or humid environments and industrial-grade connectors for tough mechanical conditions.

The importance of modular automation systems in energy storage applications

Battery-based and hydrogen-based energy storage solutions are complex systems with functional safety, IT security, and explosion protection requirements. Automation systems aim for optimal control of subsystems, considering user objectives, minimum operating costs, service life, and availability. Compliance with grid connection conditions is also crucial. Simulating system design in advance is advantageous. A modular, scalable automation platform with relevant certifications reduces development times and costs for energy storage applications. Automation suppliers offer comprehensive services, including safety concept creation, IT security considerations, and programming.

Learn more about Solutions for electrification, networking, and automation in the power-to-X and hydrogen industry. and Connection technology for energy storage systems.

From the circuit diagram to the control cabinet

Control cabinet manufacturers face increasing challenges such as time and cost pressures, shortage of skilled workers, and long component lead times. Engineering software clipx Engineer helps with the planning and completion of control cabinets. Phoenix Contact is working with manufacturers to identify inefficiencies in planning and manufacturing processes, as well as media discontinuities between engineering and paper-based productions.

Planning – starting point for continuous production

Digital control cabinets can be shared effectively through computer-aided engineering (CAE) systems, which can create circuit, assembly, and wiring diagrams. Engineering software like clipx Engineer from Phoenix Contact can acquire components, parts, functions, connection cross-sections, and labeling information, and display them digitally. The software also assists in assigning accessory items, such as covers and end brackets, and provides configurators for finding necessary components. Clipx Engineer also handles tasks like inserting and setting up terminal blocks, which can be time-consuming. The software also writes data back to the leading CAE system using a two-way interface, recording it at connection points. This saves wiring time and requires fewer connection lines, reducing terminal points on terminal blocks. The engineering software serves as the central digital database for different control cabinet variants.

Uses of the generated data for the subsequent process chain of a control cabinet manufacturer

Digitally described terminal strips or control cabinets can be assembled or equipped using Phoenix Contact’s worker-assistance software in production. Consequently, this process is more efficient and consistent with clipx Engineer engineering software. The information is displayed on a screen, assisting in assembly. A pick-by-light system can be connected for additional support, eliminating the need for time-consuming document interpretation and component search. Semi-skilled employees can perform these work steps, allowing for a more focused focus on qualified work.

Learn more about clipx ENGINEER.

In its anniversary year, Phoenix Contact is investing in the power supply of tomorrow with Building 60

Phoenix Contact is investing 35 million euros in a production and technology center in Blomberg, Germany. Furthermore, the building, numbered 60, will provide 18,485 square meters of new floor space for 400 workstations. The center demonstrates the unique networking of energy, mobility, infrastructure, and building sectors, offering a blueprint for scalable solutions. The building will integrate thermal energy into a heating network using heat pumps and a 1,500 cubic meter ice storage system. The first stage will involve battery storage systems, two photovoltaic systems, and a partial DC power grid. The decision to install a DC power grid will advance the energy revolution, allowing for easier integration of renewable energy sources, battery storage systems, and e-mobility.

Building 60: Sector coupling made real

Phoenix Contact is establishing a wide-area DC bus in Building 60 to manage energy flow from the source to the load. Consequently, the company aims to connect different ecosystems through the DC bus at its headquarters in Blomberg, establishing true sector coupling and dealing with multidirectional energy flows. Notably, the main user of Building 60 is the East Westphalian company’s in-house machine building operations.

Making savings when setting up DC grids: Sustainability starting with the installation

Direct current networks can lead to significant efficiency gains by eliminating the need for multiple cables for AC power currents. Instead, two conductors are sufficient, saving up to 50% on insulation material, especially copper. Switching to direct current in the power supply from AC to DC also saves on components, making devices smaller and more efficient. This could lead to future devices connected directly to the DC power grid.

Blueprint for the All Electric Society

The company from East Westphalia-Lippe is well-positioned in the e-mobility sector, offering charging technology and DC power grid solutions. Their Charx product range focuses on fast vehicle charging with direct current. Their expertise in high DC powers allows them to transfer this expertise to industrial applications, linking factory automation with building technology and regenerative power generation.

Learn more about DC power grids in industry.

Modular infrastructure charging sockets

User-oriented charging infrastructure

Modularity for more efficiency

Sophisticated design

Increased safety through smart features

Increase in user comfort

Learn more about the new modular AC charging sockets.

Easier identification, management, and security for OPC UA devices and applications

Access point to the central certificate management

Real-time client notification

Identification of devices in a network

Remote configuration

Read more about PLCnext Technology.

Cost-efficient, quick to respond, and reliable with the mGuard Secure Cloud

Implementation either on premises or in the cloud

Flat-rate service for reliable VPN connections to China

Compatibility with PLCnext controllers

Control over all remote access

Find out more on our website.

Learn more about the mGuard Secure Cloud.

Automation and electrification from a single source

Green hydrogen is set to replace fossil fuels in many industries, and Enapter AG has developed the AEM Multicore to make production cost-effective and flexible. Phoenix Contact experts assisted in engineering, programming, and outfitting the electrolyzer system with key components for automation and electrification. Green hydrogen’s intrinsic value stems from its ease of storage and on-demand transportation. Enapter specializes in AEM “anion exchange membrane” electrolyzers, which are more cost-effective than PEM electrolyzers while being just as flexible. The company plans to mass-produce these stacks in the medium term using a highly automated process.

Fully developed AEM stacks for series production

Enapter has introduced the AEM Multicore 450, a modular, preassembled container capable of producing up to 450 kilograms of hydrogen per day. The multicore consists of 420 AEM stack modules, each with a 2.5-kilowatt power, allowing for greater flexibility and greater process redundancy. The container also includes power supply, regulation of the electrolysis process, heat dissipation, and monitoring of process parameters, including hydrogen purity, through sensors. The fully developed stacks have already been sold in large quantities.

Close collaboration in the area of functional safety

Phoenix Contact supported Enapter, a company that developed a power supply and controller for a 1-megawatt system. The company’s services range from the development of the first small test system to the commissioning of the 1-megawatt system. Phoenix Contact’s project manager, Ayhan Birinci, highlighted the importance of functional safety in these projects. The team started working on a risk assessment before the design phase, which laid the foundation for essential design elements, including the controller. The software for the safety controller was compiled by Phoenix Contact engineers. Andreas Lautmann, Business Development Manager for power-to-X, emphasized the importance of a structured, well-documented process for design and engineering for the safety of the overall system. Furthermore, two Phoenix Contact programmers assisted the Enapter team in building a smaller test system with ten electrolysis stacks.

A challenging market situation, particularly regarding microchips

The team worked on planning control technology, which was revised seven times before the control cabinets were built. The departure of the original system planner in spring 2022 added extra work. The final changes were made during the design freeze in December 2022. Constructing the control cabinets was challenging due to supply chain issues, particularly with microchips. Phoenix Contact and Enapter worked together to keep the ambitious commissioning date, with the AEM Multicore 450 system inaugurated on May 24, 2023.

Control cabinets fully equipped with Phoenix Contact components

Phoenix Contact has installed components and systems in an electrolyzer, including connectors for sensors and controllers, and a PSU compartment for control. The control cabinets are equipped with Phoenix Contact components, including real-time and safety-oriented control technology up to SIL 3. The superordinate system controller is built with PLCnext products, fulfilling functions like ventilation, water pretreatment, emergency shutdown, fill level monitoring, and electrolyte solution supply. In-house 24 V DC power supplies, signal converters, and connection technology are also included.

Compact AC/DC converters

Phoenix Contact’s Charx power system converts 400-volt AC voltage into direct current for electrolysis. The original converters were not suitable for controlling electrolysis, leading to a replacement with a Charx series converter. The converter is more compact and efficient, ideal for installation in larger systems. Enapter ordered a complete set of AC/DC converters in mid-2022, enhancing efficiency and optimizing the PSU compartment’s cooling system.

Smooth modification of the first system

Enapter has received orders for seven more AEM Multicore systems since its first system was inaugurated in May 2023. Phoenix Contact is also able to play its part here by supplying a complete solution package of services. Enapter CEO Sebastian-Justus Schmidt stated that AEM technology will make hydrogen more economical than fossil fuels. Pre-series maturity for AEM Multicore is projected for 2024 due to strong demand. Andreas Lautmann expects IT security importance with IEC 62443 certification and integration into existing systems.

Find out more on our website.