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

Phoenix Contact’s Charx connect modular AC charging sockets offer manufacturers the ability to customize their charging stations and home chargers. with a range of cover types, temperature sensors, and actuators. These flexibly designed sockets facilitate the creation of tailored, application-oriented charging infrastructure.

User-oriented charging infrastructure

AC charging stations with charging sockets are versatile for home, work, and road use. Moreover, manufacturers can integrate additional features to make charging easier for users. Applications include private-sector carports and garages, semi-public sector, this includes charging employee cars in parking garages. The role of AC charging sockets varies depending on the location and customer needs, as installation costs vary depending on location.

Modularity for more efficiency

The Charx connect modular charging socket offers several advantages. Firstly, flexibility, low-cost warehousing, and time savings for installation and maintenance. Secondly, its modular design with fully molded contacts enhances its durability and outdoor use. Additionally, the charging socket’s installation is simplified by direct contact on the protective cover with LED status indicator, and power is routed via screws.

Sophisticated design

Charx Connect modular, an AC charging socket, won the German Design Award 2023 in the “Special Mention” category for its modular principle, allowing manufacturers to design charging stations with flexibility in shape and design. The socket also features an optional LED status indicator that can be controlled in all RGB colors, allowing manufacturers to match individual color values to their corporate design.

Increased safety through smart features

Charx Connect modular is the world’s first charging socket with integrated temperature measurement, allowing controllers to interrupt charging if overheating occurs. It also features a mechanical touch protection system, a shutter, which complies with international standards, preventing direct contact and vandalism. The sockets are easy to operate with one hand, offering IPXXD protection. The modular concept also offers a choice of interlock options.

Increase in user comfort

The modular charging socket prioritizes user comfort and safety, featuring a colored LED display for quick charging status overview and one-handed operation, highlighting the product’s well-thought-out design.

Learn more about the new modular AC charging sockets.

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

OPC UA is a machine-to-machine communication protocol. This protocol can seamlessly connect machine networks and company networks by transmitting machine information and defining data. Furthermore, it enables an efficient process setup between controllers and higher-level software layers. In addition, the software update model can be employed for asset management, encompassing tasks such as software installation, firmware updates, and backup. Finally, OPC UA provides certificate-based communication, ensuring secure data exchange with assets. Read more.

Access point to the central certificate management

The Global Discovery Server (GDS) in OPC UA allows cross-subnet discovery services and interfaces for a central certificate management system. It manages CA-signed and self-signed certificates, trustworthy lists, and CRLs. The GDS plays a crucial role in managing CA-signed certificates, generating initial OPC UA application certificates, updating CRLs, trust lists, and renewing applications. It ensures the efficient operation of OPC UA systems.

Real-time client notification

The GDS Push Service is a feature of the OPC UA Global Discovery Server that provides real-time notifications to clients about new endpoints or changes in existing endpoints and applications. This service allows clients to subscribe to notifications about specific events, ensuring they are always updated on network adaptations. It can also work with the OPC UA Pub/Sub protocol for efficient event notifications. This feature enhances data transmission in industrial and IoT systems.

Identification of devices in a network

The OPC UA Global Discovery Server (GDS) is a valuable tool for device management tools, such as the Device and Update Management system from Phoenix Contact. It supports identifying and managing OPC UA-enabled devices and applications, providing a central location for endpoint administration. The GDS also manages security, including certificates and security directives, ensuring secure communication. It also provides real-time notifications about network changes, allowing the tool to automatically adjust configurations when needed.

Remote configuration

Automated commissioning of new or replacement devices is crucial in the All Electric Society, as it saves time and money. Zero-touch or one-touch provisioning allows for remote configuration of intelligent end devices, saving time and money. An intelligent device management tool, combined with an OPC UA Global Discovery Server, enables this process. The OPC UA standard allows corresponding scenarios to be implemented regardless of the device manufacturer.

Read more about PLCnext Technology.

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

Phoenix Contact offers secure remote access solutions for ship maintenance, allowing efficient work from afar. In addition, automation is becoming more common in fleets, enabling automated processes. As a result, manufacturers optimize these systems to improve efficiency. However, malfunctions or system failures can occur, demanding fast action. To address this, Phoenix Contact’s remote maintenance solutions utilize the internet for worldwide communication. Consequently, this enables service personnel to connect securely and reliably with maritime systems without detailed IT knowledge.

Implementation either on premises or in the cloud

Phoenix Contact provides users with two solutions for maritime systems: on-premises variant and public cloud. On-premises uses a private remote access infrastructure, like FL mGuard Centerport, for setting up VPNs or secure VPN connections. This allows users to store data locally and meet compliance requirements without external providers. Public cloud, like Phoenix Contact’s mGuard Secure Cloud, provides a ready-to-use remote maintenance solution and is always up-to-date, meeting European data protection standards (DSGVO, Datenschutz-Grundverordnung). IT-savvy employees are required to manage configurations, updates, backups, and restoration processes.

Flat-rate service for reliable VPN connections to China

The mGuard Secure Cloud service addresses the need for secure VPN connections in China, enabling 99 percent availability without compromising access security. The China VPN+ flat-rate service allows end-to-end encryption in accordance with Chinese National Network Security, ensuring 99-percent availability without compromising access security. The robust security router of the new mGuard platform can transfer nearly 1,000 Mbps of data, allowing high-quality video transmissions. mGuard devices use trusted IPsec security protocol and advanced mechanisms, ensuring confidentiality, authenticity, and integrity of all communicated data. They can be easily integrated into existing systems using the graphic VPN Builder in the cloud.

Compatibility with PLCnext controllers

The mGuard Secure Cloud is compatible with mGuard security routers, other VPN clients, and PLCnext controllers from Phoenix Contact. It allows users to establish a direct VPN connection to a PLCnext controller, which is certified by an independent accreditation organization in accordance with IEC 62443-4-1 and IEC 62443-4-2.

Control over all remote access

The mGuard Secure Cloud allows secure remote maintenance by requiring a security router or PLCnext controller. VPN connection configuration is done using VPN Builder wizards, requiring no in-depth knowledge. Service personnel need an end device with a certified VPN software client and a secure standard browser with internet access. Remote maintenance is performed on an intuitive web interface, saving costs compared to on-site visits. The premium license for the mGuard Secure Cloud includes China VPN+ costs around 3,600 euros per year, and every flight not taken is better for the environment.

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.

A Digital Factory approach that conserves resources and is economical at the same time

Phoenix Contact focuses on sustainability and balancing its carbon footprint by developing automation solutions. The company aims to help other manufacturing companies achieve carbon neutrality by electrifying loads, creating energy transparency, and using renewable energies in daily operations. The All Electric Society concept describes a future where renewable energy is available worldwide in sufficient quantities and economically. Phoenix Contact’s holistic digitalization concept, “Digital Factory now,” integrates consumption data into distribution, visualization, and control of process data, aiming to control energy consumption and achieve carbon-neutral production.

Recording, evaluating, and managing loads

Phoenix Contact has developed an architecture called “More than Measure Energy” to integrate existing systems into modern IT systems. This architecture includes a Data Collection Box for secure integration of process and consumption data. Users can choose between a standardized Data Collection Box or a fully customized version. Phoenix Contact uses a programmable logic controller (PLC) from the PLCnext Control product family in its Digital Factory at the Bad Pyrmont location for secure communication with the OT world and IIoT devices. The company also provides solutions in the immediate production environment as well as its own EMMA cloud service for energy management.

Turning findings into optimization measures quickly

A soldering system in the Digital Factory in Bad Pyrmont integrates energy-saving measures by analyzing energy data from a Data Collection Box. The system identifies standby energy consumption and allows for dynamic switch-off and switch-on times based on order data and energy data analysis. This allows for more efficient order planning in the long term. Phoenix Contact’s “MLnext” machine learning solutions can help predict field-level information, such as manual workstation utilization status, ensuring data availability. A holistic approach to optimization involves collecting and analyzing data throughout the entire production process using AI-based algorithms.

Energy data reflects the system behavior

Energy data can be used to evaluate machine performance, availability, and product quality using artificial intelligence (AI). Anomalies can be detected and quantities and operating states can be predicted. Collecting and storing data benefits users differently, accelerating the payback period and revealing potential. The Big Data approach applies, focusing on data-driven patterns and providing suggested solutions to domain experts. Collecting energy data leads to direct and indirect benefits, ensuring resource-efficient and competitive production.

Find out more about Digital Factory here.

Find out more about PLCnext.

Cost-saving solution with lots of potential

G.hn technology expands network range and speed by extending the physical limitations of Ethernet transmission. This enables distances of up to 1000 meters over simple 2-wire cables at a maximum data rate of 1 Gbps. This technology is beneficial for industrial applications, such as computers, automation controllers, surveillance cameras, traffic regulators, building automation, and household appliances. It provides longer communication paths and a more simplified cabling structure.

High data rate and good transmission quality

G.hn, or Gigabit Home Networks, is a carrier frequency method originally designed for home networks. It offers high data rates and good transmission quality on every line. It can adapt to existing line attenuation. Moreover, it can bridge cable lengths up to 1000 meters, This value exceeds the standard Ethernet range by a factor of 10. G.hn offers greater flexibility for retrofitting systems and simplifies network structure, allowing complex topologies to be implemented even with passive connections. Thanks to these benefits, the end result is a standard that will become more important in future industrial, infrastructure, and IoT applications.

Further use of the existing cabling

Phoenix Contact’s new Gigabit Ethernet extender product family allows users to convert Ethernet communication to G.hn communication. This reduces effort and costs. The technology allows for the use of various transmission media, such as twisted pairs, coaxial conductors, or unused power cables, making it a cost-saving alternative to fiber-optic cables for Ethernet connections exceeding 100 meters.

Especially suitable for video surveillance systems

G.hn technology is ideal for applications with high data volumes, such as those found in video surveillance systems due to its bandwidth and transmission distance. It can integrate remote cameras with high bandwidth requirements into the network, reducing the distance between cameras and network components. This technology replaces analog cameras with IP cameras. Consequently, allowing existing cabling to be used and maintaining high video image resolution without sacrificing resolution.

Easy plug-and-play installation

G.hn, a technology that distinguishes itself from other technologies like SHDSL, VDSL, and SPE, describes both the physical layer (first layer) and data layers (second layer) of a network. This way, G.hn opens up the option to build and manage more complex network topologies. Phoenix Contact’s Gigabit Ethernet extenders allow you to interconnect network devices in various topologies, including line, star, and tree structures. They can manage up to 15 devices, which do not require any settings to be made, However, users should note that the maximum data rate of 1 Gbps may decrease as the number of extenders increases.

Find out more about Gigabit Ethernet extenders.

Less fossil-fuel energy and lower emissions

Phoenix Contact offers a solution for energy-intensive glass manufacturing to achieve Net Zero climate goals, using PLCnext Technology’s IIoT framework. An auxiliary heating system was integrated into a glass plant in Egypt in 2009 to enhance glass quality and reduce emissions. This decision now plays a crucial role in transforming the glass industry into sustainable factories amidst rapid changes driven by factors like climate change and digitalization.

Capturing all utilities efficiently, and intelligently, with minimal process interventions

The “All Electric Society” envisions a world where renewable electrical energy is the main energy source, abundant, cost-effective, and environmentally friendly. Industries, like glass manufacturing, must adapt their processes across various areas, from raw materials to production, for sustainable climate strategies. Existing factories using different media face challenges, especially in optimizing fuel and water use efficiently and resourcefully. These improvements should be applied in both traditional and modern networked factory settings.

ML-supported process optimization with the PLCnext Technology

Early detection of anomalies in sensors and actuators along the glass manufacturing process brings several benefits. Firstly, it prevents disruptions, allowing for uninterrupted production. Secondly, it improves equipment efficiency, resulting in cost savings. Additionally, it optimizes fuel-air ratios and electrical heating, reducing energy consumption. Furthermore, it enables smart monitoring of various parameters for enhanced process control. To assist specialists in process optimization, Phoenix Contact offers MLnext, a machine learning system available on the PLCnext Store online marketplace. To ensure global accessibility, Phoenix Contact has introduced the Digital Factory Now initiative. This initiative provides open and standardized automation solutions based on PLCnext Technology. Consequently, it facilitates tailored solutions, from glass production to building-specific applications, in alignment with the goals of the All Electric Society.

International certification for safety and security

The OT Security certification of the PLCnext Control family by TÜV Süd, aligned with IEC 62443-4-2, along with existing safety certifications, establishes new industry standards. IEC 62443 is the primary global standard for OT security, while functional safety is defined by standards like IEC 61508, ISO 13849, and IEC 62061. Future automation solutions must bridge both perspectives. Due to the need for protection against tampering and remote access considerations, OT security is gaining prominence in the upcoming Machinery Directive. The certified PLCnext Control family already complies with the Machinery Directive requirements.

Field-side signal connection using smart signal conditioners

Users want to optimize fuel-to-air ratios securely using a parallel sensor system or their DCS. They aim to incorporate AI and implement a segmented network per IEC 62443. This is achievable by connecting signals through PLCnext Edge Devices or utility metering control cabinets, enabling real-time data exchange with IT/cloud, ERP/MES, or DCS systems. The glass industry can now advance sustainability and secure networking with these solutions.

Find out more about Digital Factory.