Joint research project: DC-INDUSTRIE2 – Direct current for the factory of the future

DC-INDUSTRIE2 |

Project introduction: DC-INDUSTRIE2

Dr. Hartwig Stammberger, Prof. Dr.-Ing. Holger Borcherding

Date: May 18, 2020

Projektvorstellung DC-INDUSTRIE2

Dr. Hartwig Stammberger Prof. Dr.-Ing. Holger Borcherding

(Eaton) (TH OWL)

Seite 2 18. Mai 2020

DC-INDUSTRIE2

Overview on the research project DC-INDUSTRIE2

• Funded by the German Federal Government,

BMWi

• Funding codes: 03EI6002A-Q

• Duration: 3 years until Sep. 2022

• 39 partners of industry and research

• Objectives:

• Safe and robust energy supply of production plants

• Mains-supporting connection to the superior supply

mains

• Simple project planning

• Maximum use of decentralized, regenerative energy

generation

• Proof evidence in

• 6 model plants and transfer centers

DC grid

Seite 3 18. Mai 2020

DC-INDUSTRIE2

Status quo: Topology in an industrial AC-factory grid

=3~

3~=

=

3~

-+

==

AC-distribution

Transformer Emergency power

(extremely rare in industry)

Passive loads

(light, heat,

…)

Speed-

variable

drives

Mains-synchr.

drives (fixed

speed)

Machines and

robots with AC-

supply

24V-power

supply (PLC, I/O,

sensors, …)

1~ 230V /

3~ 400V

sockets

3~=

Energy

flow

24V

3~

Seite 4 18. Mai 2020

DC-INDUSTRIE2

Vision: Topology in an industrial DC-factory grid

DC-mains

Transformer

Supply and

feedback

DC 650 V

=3~

Speed-variable

drives (with

rectifier)

Passive loads

(light, heat, …)

==

Energy storage

==

==

-+

==

Energy generator

1~ 230V /

3~ 400V

sockets

=3~

Machines and robots

with DC-supply

Energy flow

24V-power

supply (PLC, I/O,

sensors, …)

24V

3~=

=

Seite 5 18. Mai 2020

DC-INDUSTRIE2

Advantages of DC-Grid for industrial plants

• Energy efficiency

• Less transformation and transport losses

• Use of recuperation energy

• Direct use of renewable energy sources

• Peak power reduction through suitable storages

• Resource efficiency

• Reduction of copper use (cables)

• Lower equipment costs and space savings due to the elimination of power electronics

• Mains stability

• Additional investments for mains filtering and compensation can be omitted and existing grids are supported

• Production failures through mains disturbances can be prevented/reduced

• Industrial Smart DC-Grid / flexibility

• Infrastructure for intelligent control of energy flows enables advantages in energy purchasing

• Supports modular machine concepts

DC grid

Seite 6 18. Mai 2020

DC-INDUSTRIE2

System concept: Division into load zones

Load zones

➢ … form a logical unit

➢ … include components with strong

functional dependencies to each other

➢ … include sufficient capacity in order to

separate switch-frequency

compensation processes from the DC-

grids

➢ … are connected to the DC grid via DC

protection box

Seite 7 18. Mai 2020

DC-INDUSTRIE2

System concept operating voltage

Two mains voltages are defined for the DC-mains

• 650 V: For controlled supply and uncontrolled at 480V-mains

• 540 V: For uncontrolled supply at the 400V-AC-mains

• Rated operation

• Unlimited functionality of the units

• Stationary over/undervoltage

• Units can be operated permanently within this range

• The functionality should not be limited (e.g. power derating)

• Active participants counteract the voltage deviation

• Transient over/undervoltage

• Units may lose function, but must resume function after voltage recovery

• Voltage should only remain in this range for a limited time

• Switch-off limits: 400 V / 800 V

• Units switch off permanently

• Manufacturers can specify different rating data (e.g. rated power) for

both mains voltages

VDC,N =

485…625V

VDC,N =

585…750V

Uncontrolled Controlled/ 480 V

400 VAC uncontrolled

Seite 8 18. Mai 2020

DC-INDUSTRIE2

System concept: Method for voltage stability

a) Uncontrolled operation (basic network):

• No active control of the DC-voltage (operation with diode rectifier)

b) Characteristic-based control (decentralized group control):

• All active feeders regulate their power depending on the level of DC voltage

• The characteristic is defined by a non-linear characteristic curve

• No communication required

c) Extended decentralized group control:

• Setting of the characteristic curve is changed by a central control unit during operation

• Only slow communication required

d) Central voltage control:

• Central control unit provides the specified power values for the supply units

• Fast communication required

By choosing the control method, very simple as well as complex DC-grids with several

generators can be built

Seite 9 18. Mai 2020

DC-INDUSTRIE2

System concept DC-INDUSTRIE: Framework conditions

• Requirements to the system concept

• Open for all (manufacturer-independent)

• Universal use – not only in model applications

• Consumers and generators can be integrated

• The DC-grid is scalable

• Classification of the system concept

• No compatibility to other DC-grids required

(household, data centers)

• No energy generation system according to

VDE-AR-N4105 (main energy flow from the

AC-grid)

• Use in industrial environment (important for

EMC)

• No use of overhead lines

• Extent of the plant

• Easy DC-bus coupling

• Few units

• Little installation effort

• Use of braking energy

• Medium-size plants (extent 25 m … 75m)

• Integration of energy storage

• Reduction of peak power

• Increase of system availability

• Hall supply (extent >50 m)

• Coupling via own transformer

• Integration of regenerative energy

• Mains-supporting (reactive power compensation)

Seite 10 18. Mai 2020

DC-INDUSTRIE2

DC-INDUSTRIE2: Extension to production halls

Quelle: Fraunhofer IPA

Seite 11 18. Mai 2020

DC-INDUSTRIE2

A few figures of the project…

• 39 companies/institutes

• Approx. 135 technical project

staff

• 1100 people-months

• 6 model applications and transfer

centers

86

49

Persons

New

DC-INDUSTRIE

18

21

Members of consortium

New

DC-INDUSTRIE

18

21

Members of consortium

Funded

Associated

Seite 12 18. Mai 2020

DC-INDUSTRIE2

Positioning of the project

For the "Energy use in industry and trade" of the 7th energy research programme

"Innovations for the energy turnaround" of the Federal Ministry of Economics and Energy

• Criteria and objectives:

• Upgrading of the electricity grid infrastructure and its orientation towards feeding a high proportion of

renewable energies into the grid

• Improve the environmental compatibility, economic viability and resource efficiency of electricity grids while

maintaining a high level of supply reliability

• Further development and flexibilization of existing resources

• Components for grid coupling of renewable energy plants, storage facilities and consumers

• Use of new materials in electricity grids and in the grid integration of renewable energies

• Research into novel selective protection concepts

• Research and development of new and existing measurement and monitoring concepts

• Development of test concepts for novel components

• Increased component availability through new monitoring and maintenance approaches

Seite 13 18. Mai 2020

DC-INDUSTRIE2

Objectives and approach

Objectives:

• Safe, robust, highly available and mains-supporting

with distributed supply

• Safe and robust energy supply of production plants

• Mains-supporting connection to the energy supplying mains

• Maximum use of decentralized renewable energy generation

Approach:

• "Openness and simplicity will become safe and intelligent“

• Based on the open DC-grid network as defined in DC-INDUSTRIE

• Extension to factory hall level

• Combining safe operation through protection technology with mains-supporting connections and

optimizing flexibility, modularity and availability

• Testing, evaluation and optimization of results in the model plants and in transfer centers

Seite 14 18. Mai 2020

DC-INDUSTRIE2

Work packages of DC-INDUSTRIE2

• Reflection and extension of the system concept of DC-INDUSTRIE

• Research and provision of components for realization of energy-efficient DC-grids

• Further development of intelligent DC protection elements and structure components for

safe operation of DC-grids

• Development and provision of methods for easy project planning and set-up of DC-grids

(Systems Engineering)

• Operation of the iDC-grid and implementation into superior mains structures (energy and

mains management)

• Testing, evaluation and optimization in model plants (Daimler, Homag and BMW) and in

transfer centers

→ Work from 2019 to 2022

Seite 15 18. Mai 2020

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Project partners

Seite 16 18. Mai 2020

DC-INDUSTRIE2

Information sources and publications

• DC-Industrie-Homepage www.dc-industrie.de

• Computer & Automation Fachartikelreihe

• Enargus zu DC-Industrie

• Pages of Hannover Fair 2019, booth of DC-INDUSTRIE of the ZVEI:

• https://experience.dc-industrie.zvei.org/

Seite 17 18. Mai 2020

DC-INDUSTRIE2

Assoziierte Partner: ABB Stotz-Kontakt; AMK Arnold Müller; Audi; Bauer Gear Motor; Bender; Danfoss; DEHN; ESR Pollmeier; Gerotor;

Harting; Jean Müller; KUKA; LEONI; Maschinenfabrik Reinhausen; Paul Vahle; Puls; Rittal; SEW-PowerSystems; Siemens; TU Ilmenau; Wöhner