Carbon neutrality and decarbonization are reshaping industrial energy strategy. The All Electric Society vision describes a future in which renewable electrical energy is available in sufficient quantities and at affordable prices. Reaching that goal requires sector coupling, intelligent energy management, and more efficient power distribution. DC grids in industry offer a practical route forward.

Why move toward a DC Factory?

A factory DC grid can improve energy efficiency by recovering braking energy and reducing conversion losses. It can also integrate photovoltaic systems, battery storage, and EV charging stations directly. In suitable applications, recuperation can balance peak loads substantially, while fewer cables can reduce copper consumption.

The economic case is therefore compelling. However, a successful DC factory needs more than efficient components. It requires a coordinated concept covering objectives, topology, converters, protection, arc analysis, and energy management.

Start with objectives and operating conditions

Planning begins by defining what the DC grid must achieve. Engineers should evaluate recuperation potential from robots or storage and retrieval machines, required security of supply, connected loads, charging infrastructure, base loads, and startup peaks. Weather forecasts and electricity market prices may also influence the preferred energy strategy.

Fire protection, safety, and cybersecurity guidelines require equal attention. These inputs support an initial assessment of economic viability and risk before the project moves into detailed design.

Select the topology and voltage level

According to the ODCA and VDE SPEC 90037, normal operation takes place within a nominal band of 620 V to 750 V. This range balances component selection, losses, control reserves, and safety requirements.

A central DC busbar forms the power backbone. AC/DC coupling connects the factory to the AC grid, while DC/DC couplings integrate PV, battery storage, EV charging, lighting, and production equipment. Zoning, field distributors, or redundant feeds can add selectivity and resilience.

Design conversion, grounding, and protection together

Smart breakers enable arc-free, bidirectional disconnection. The ELR HDC-PT-24/650/55-IOL interrupts semiconductor current within 10 µs, then isolates both poles electromechanically. It also supports ground-fault, short-circuit, line, residual-current, overvoltage, and undervoltage protection. Arc analysis remains essential because tripping time directly affects arc energy and the personal risk assessment.

Manage energy without compromising availability

From potential to practical implementation

A DC factory can increase the sustainable use of energy while reducing associated costs. The All Electric Society Factory demonstrates the approach through PV, battery storage, charging infrastructure, a partially integrated DC grid, heat pumps, and 1,500 m³ of ice storage. With more compatible products reaching the market, industrial DC grids are becoming not only sensible, but manageable.

Ready to explore the potential of a DC grid for your production environment?

Learn more about the technologies, components, and planning considerations for building a safe, reliable, and energy-efficient DC factory. Learn more about industrial DC grids

New Approach to LPIT Protection Testing

Modern switching devices must deliver more than operational safety and availability. They must also support resource conservation, occupational safety, and efficient operation throughout the system life cycle. As power electronics become more integrated into the grid, the frequency spectrum used to assess grid conditions expands, while conventional converters increasingly reach limits caused by nonlinear characteristics and saturation effects. Low-power instrument transformers, or LPITs, provide an alternative. Their compact design supports space-saving switchgear concepts for modern medium- and high-voltage systems. However, LPITs also change measurement and protection architectures. Instead of power-carrying secondary circuits, they provide low-level sensor signals. Consequently, periodic protection testing requires a new approach.

Why traditional testing methods fall short

Traditional testing methods are only partly suitable for LPIT-based switching devices. Manual wiring, serial switching, and changes to measurement circuits take time and introduce potential errors. They can also affect occupational safety, system availability, and operational processes. Operators therefore need a testing concept that provides reliable signal transmission and enables protection tests without disturbing existing wiring.

LPIT signals are more sensitive than conventional converter secondary circuits to electromagnetic interference, contact transitions, and inadequate shielding. For that reason, robust, continuous shielding is a fundamental system requirement.

Continue reading →

What challenges does the machine building and systems manufacturing industry face, and how can innovative connectors help address them? Simple, standardized connection processes that can be automated as much as possible are becoming a key driver of efficiency and system availability.

The machine building and systems manufacturing industry is facing profound challenges that are placing increasing pressure on established production processes. In many industrialized nations, experienced professionals are retiring from the workforce, while there is a shortage of qualified young talent. Technical professions that involve hands-on work and experience, such as mechanical engineering, systems manufacturing, and control cabinet building, are being hit especially hard.

Companies must therefore carry out complex electrical engineering tasks with fewer staff. The demands for flexibility, modularity, and cost-effectiveness are increasing, while times-to-market for new machines and systems are shrinking. Industrial companies expect customized solutions, short lead times, and rapid commissioning.

Continue reading →