{"id":3685,"date":"2025-12-25T15:51:18","date_gmt":"2025-12-25T11:51:18","guid":{"rendered":"https:\/\/blog.phoenixcontact.com\/marketing-ae\/?p=3685"},"modified":"2025-12-25T15:51:18","modified_gmt":"2025-12-25T11:51:18","slug":"dc-power-grids-in-industrial-applications","status":"publish","type":"post","link":"https:\/\/blog.phoenixcontact.com\/marketing-ae\/dc-power-grids-in-industrial-applications\/","title":{"rendered":"DC power grids in industrial applications"},"content":{"rendered":"\n

Industrial DC grids are already a reality. Companies can implement and operate them today and benefit from their efficiency. Schaltbau in Munich and Phoenix Contact in Blomberg demonstrate this through best\u2011practice examples.<\/p>\n\n\n

\n
\"\"<\/a><\/figure><\/div>\n\n\n\n\n\n\n

From idea to implementation: What needs to be done?<\/strong><\/h2>\n\n\n\n

Direct current is an increasingly important topic. Beyond stand\u2011alone solutions for charging parks and DC grids<\/a> in commercial buildings, DC systems represent the future of industrial applications. In the context of the All Electric Society, where carbon\u2011neutral energy sources dominate, direct current emerges as a key technology with numerous advantages.<\/p>\n\n\n\n

Whether retrofitting a plant or building a new one, the first step is to identify which loads should run directly on DC, including lighting and technical building utilities, PV systems, storage, and production equipment. The choice of storage technology and its installation location, whether centralized or near the relevant machinery, must also be evaluated. Another key factor is whether the plant will include charging stations for electric vehicles. \u201cAt the outset, designing a DC grid is no different from designing an AC grid,\u201d says Matthias Unruhe, Director Corporate Facility Management at Phoenix Contact.<\/p>\n\n\n\n

Once project planning is complete, implementation begins, raising questions about voltage ranges and component selection. For industrial applications, the Open DC Alliance (ODCA) provides a system concept that addresses many of these points. <\/p>\n\n\n\n

\"On<\/figure>
\n

Schaltbau and Phoenix Contact offer a broad range of DC\u2011capable components, and major hurdles, like high power\u2011electronics costs, have decreased significantly. Their close cooperation has already resulted in two DC production sites: the Schaltbau NExT Factory<\/a> in Velden and the Phoenix Contact All Electric Society Factory in Blomberg.<\/p>\n<\/div><\/div>\n\n\n\n

Potential and the (initial) obstacles of DC technology<\/strong><\/h2>\n\n\n\n

DC systems in production and logistics offer major energy\u2011saving potential. Dynamic loads like industrial robots can cut peak loads by up to 85% and boost efficiency by up to 20%. Large motors with frequency converters also benefit, as do DC sources, loads, lighting, and charging stations. Even so, the path from planning to implementation was difficult for the early DC pioneers.<\/p>\n\n\n\n

When planning for the Schaltbau NExT Factory began in 2019, there were almost no suitable components or standards for DC technology. Grid operators also had little experience integrating DC systems into the public grid, and finding qualified planners and installers was challenging due to the limited number of experts.<\/p>\n\n\n\n

The situation has improved in recent years, supported by intensive research and multiple pilot projects that tested DC solutions under real conditions. These efforts are now paving the way for broader practical implementation.<\/p>\n\n\n\n

Phoenix Contact had similar experiences. \u201cAfter our initial deliberations, one question remained: Where would we obtain the components?\u201d says Matthias Unruhe. The company\u2019s broad portfolio provided the solution, including TRIO HP power modules for DC grids and VAL\u2011MB DC surge protection. Phoenix Contact\u2019s long\u2011standing research into direct current also enabled the early development of key components such as the ELR HDC miniature circuit breaker and the ArcZero DC connector, both now used in the All Electric Society Factory.<\/p>\n\n\n\n

Ultimately, implementing DC systems is less complex than it may seem. With suitable components, regulatory progress, and growing expertise, especially through the Open DC Alliance, adoption is becoming increasingly practical. \u201cRecent developments have made DC projects much easier to implement,\u201d notes Schaltbau expert Christoph Neulinger. His pragmatic advice: \u201cJust do it.\u201d<\/p>\n\n\n\n

The All Electric Society production building of the future<\/strong><\/h2>\n\n\n\n

The All Electric Society Factory leverages the full potential of direct current, achieving maximum flexibility, efficiency, and stability by coupling all relevant sectors via DC. It also optimizes the entire energy chain, from generation and distribution to storage and consumption, since many of these areas already operate largely on a DC basis.<\/p>\n\n\n\n

The DC grid is supplied with 700\u202fkW from the AC grid, while PV\u2011connected DC\/DC converters add 120\u202fkW directly to the DC bus. Two branches feed production machines and recover regenerative energy from robots and drives. Ten DC charging points (2 \u00d7 150\u202fkW, 8 \u00d7 60\u202fkW) serve the parking area. Surplus energy is stored in the DC\u2011coupled battery system or fed back into the public AC grid via bidirectional converters. PLCnext Engineer manages sector\u2011level and overall DC grid loads. The ELR HDC safely switches DC loads, combining protection, switching, monitoring, precharging, and network capability. ArcZero DC connectors enable arc\u2011free plug\u2011in connections, while EMpro DC meters record all energy flows. The industrial DC grid also serves as a research platform and public blueprint.<\/p>\n\n\n\n

The DC high-bay warehouse system<\/strong><\/h2>\n\n\n\n
\"DC<\/figure>
\n

Logistics is another area where DC technology\u2019s potential can be fully realized. Schaltbau\u2019s automated small\u2011parts warehouse, with 50,000 storage locations and 5,000 daily transport operations, forms the logistics backbone of the NExT Factory. Ninety Autonomous Robotic Carriers support the latest expansion. The entire system, including the ARCs, is highly energy\u2011efficient, with a peak power of only 18\u202fkW, far below the roughly 120\u202fkW typical of AC\u2011based alternatives.<\/p>\n<\/div><\/div>\n\n\n\n

DC for forklift trucks<\/strong><\/h2>\n\n\n\n

A key element of Schaltbau\u2019s logistics concept is the integration of two bidirectional DC\u2011grid\u2011compatible chargers for its forklift fleet. These are developed together with Jungheinrich and Industrie Elektronik Brilon specifically for the NExT Factory.<\/p>\n\n\n\n

Analysis shows that forklift trucks are often idle during each shift. The DC\u2011grid charging concept uses these idle periods for controlled battery discharge and grid feedback, boosting on\u2011site energy storage. This helps cut power peaks and increase PV self\u2011consumption. Dynamic electricity pricing adds further benefits: stored energy powers the building when prices are high, and the fleet\u2019s batteries are recharged when prices are low.<\/p>\n\n\n\n

This strategy not only lowers energy costs but also extends battery service life.<\/p>\n\n\n\n

Read more about the All Electric Society Factory<\/a> and DC grids<\/a>.<\/p>\n","protected":false},"excerpt":{"rendered":"

Industrial DC grids are already a reality. Companies can implement and operate them today and benefit from their efficiency. Schaltbau in Munich and Phoenix Contact in Blomberg demonstrate this through best\u2011practice examples.<\/p>\n","protected":false},"author":357,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[],"class_list":["post-3685","post","type-post","status-publish","format-standard","hentry","category-uncategorized"],"yoast_head":"\nDC power grids in industrial applications | Middle East<\/title>\n<meta name=\"description\" content=\"Phoenix Contact\u2019s new building in Blomberg demonstrates how an industrial DC grid ensures greater energy efficiency.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/blog.phoenixcontact.com\/marketing-ae\/dc-power-grids-in-industrial-applications\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" 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