Research Focus on Energy Storage in Production: Challenges and Opportunities

The manufacturing industry faces the challenge of optimizing energy consumption while driving the integration of renewable energy sources. Frequent acceleration and braking operations in production machines cause high, short-term power peaks, which require mighty electrical infrastructure and lead to losses in partial load conditions. Energy storage systems offer tremendous potential here: they enable demand-optimized use of renewable energy directly at the production site and create valuable temporal decoupling between energy generation and consumption. However, there has been a lack of intuitive and comprehensive tools to assist planners in designing and sizing such complex systems.

Diverse Applications for ESiP Analyzer Focus: From Peak-Shaving to PV Storage

In addition to classic peak shaving, the new design and simulation tool enables precise modeling of other use cases. These include, for example, the recovery of braking energy from drives in the DC link and the implementation of uninterruptible power supply for critical production processes. The tool takes into account common energy storage technologies and various integration approaches, always incorporating the extensive expertise of Fraunhofer IWU in both energy storage and production engineering.

Comprehensive Approach: Design and Operational Management in Focus

Proposing specific design procedures for different application scenarios is a core feature of the tool. In addition, simulations include operational management factors such as system efficiency and specific production parameters. The goal is to support companies in selecting the appropriate storage technology and defining optimal operational strategies for long-term efficient and economical use.

ESiP Analyzer at a Glance

The tool supports companies in analyzing potential, planning, and integrating energy storage systems in manufacturing:

• ESiP Factory Analyzer: An initial assessment to identify potential applications of energy storage at the factory level;
• ESiP Machine Analyzer: Evaluation of potential use cases at the machine level;
• ESiP System Simulation: A detailed, in-depth analysis of applications to optimize system efficiency under various operating conditions – from transient phenomena to long-term operation. The software allows for evaluation of different topologies (AC/DC, passive DC, active DC) and the development of tailored energy management strategies.

This makes the ESiP Analyzer an ideal tool for conducting a well-founded comparison and selecting the most technically and economically viable storage solution for a specific manufacturing application.

Fraunhofer IWU at “The Smarter E Europe” in Munich

“The Smarter E Europe” combines four leading trade fairs: Intersolar Europe, ees Europe, Power2Drive Europe, and EM-Power Europe. Manufacturing companies are warmly invited to visit Fraunhofer IWU at the Saxony Economic Development Corporation’s joint booth and experience the future of energy efficiency in production firsthand. The ESiP Analyzer provides an opportunity to make industrial manufacturing more flexible and energy efficient. Visitors can look forward to:

• One-on-one discussions: the chance to talk with experts about individual energy challenges and collaboratively develop tailored solutions;
• Live demos: the IWU team will showcase the prototype of its innovative design and simulation tool using real-world application examples;
• Comprehensive support: from initial concept development to successful implementation of energy storage systems, IWU offers guidance and collaboration throughout the entire project lifecycle.