1|15 The customer magazine from Phoenix Contact | April 2015 E-Mobility in motion How Phoenix Contact is helping to shape the mobility of the future
02 Editorial UPDATE 1|15 Dipl.-Phys. Helmut Friedrich Executive Vice President Phoenix Contact E-Mobility GmbH On the way to an e-mobile future Dear readers, Is motoring on the brink of a revolution? Autonomous driving and battery- supported electric drives are the hot topics currently being discussed. While the purpose of autonomous driving is to increase convenience, the development of the electric car is driven by the fact that the world will face stricter environmental requirements in the future. Completely autonomous driving is still at the experimental stage, whereas there are already several battery-only vehicles that are being successfully driven on the roads. In addition, numerous high-volume models are already available or will be available in the near future as hybrid vehicles. Just a few years ago we were still wondering whether E-Mobility would ind acceptance, but now it is simply a question of how fast this will happen. The necessary infrastructure for charging batteries is also a prerequisite for this rapid change. The expansion of the infrastructure in individual countries is moving at very diferent speeds. Sadly, Germany is lagging far behind here. A basic requirement was already established years ago: uniform and standardized connectors for Europe, North America, China, and Japan. Phoenix Contact – working together with the automotive industry – played a leading role here. Fast charging technology in particular is a prerequisite for electric vehicles being widely accepted. With this technology it is possible to charge a car in around half an hour. To date, appropriate charging stations have only been installed in a few public locations. The Federal Chancellor's goal is to have over one million electric vehicles on the road in Germany by 2020. So we still have a lot of work ahead of us in the next ive years! We must therefore increase our eforts in the expansion of this infrastructure. Commentary 02 Helmut Friedrich Interview 03 Matthias Kübel, Volkswagen AG Cover story A irm ixture 04 Phoenix Contact ofers components and systems for modern charging technolo- gy Technology E-Mobility 08 Flexible control solution for DC charging 16 E-Mobility E-Mobility for utility and special-purpo- se vehicles Solutions for the future E-Mobility 10 Gildemeister energy solutions controls its EV charging stations with Phoenix Contact On site 07 E-Mobility Intensive promotion of E-Mobility in China Control technology 18 Network of emergency power genera- tors creates a virtual power plant New products Power-Turn high-current terminal blocks Safe Energy Control Technology WP 3000 series touch panels EH housing system 21 In the spotlight 14 A review of 20 years of the Industrial Communication Congress 22 Roland Bent new Chairman of the DKE 22 steering committee Eplan, Rittal, and Phoenix Contact pre- sent digitized production 23 Phoenix Contact creates investment company phoenixcontact.com
UPDATE 1|15 Interview 03 Well on the way The Combined Charging System has become established Matthias Kübel is Project Leader for Charging Interface Standards and Concepts at Volkswagen in Wolfsburg, Germany. He played an instrumental role in the development of the Combined Charging System (CCS) charging standard on behalf of the automobile manufacturer. The UPDATE team asked him about the background to the new standard's introduction and how the charging technology will be developed further. UPDATE: Mr Kübel, how would you describe the response so far to the new CCS standard among customers and manufacturers? Kübel: The CCS has been well received in Europe and America. For example, at the end of 2014 there were over 700 charging stations using UPDATE: What are the challenges that still exist for vehicle manufacturers and what is the situation with regard to infrastructure development? Kübel: Interoperability and the further expansion of the CCS charging infrastructure are currently the biggest issues. Vehicle manufacturers, test laboratories, and charging station manufacturers are all working together on the description of conformance tests. This will then ensure that CCS charging stations that pass this test can properly serve any vehicle with the CCS charging system. Beyond that, we need to promote the CCS in Asia. Consideration is being given to the CCS charging infrastructure in a few Asian markets, such as Korea and Hong Kong. It's a good start, but it's still not enough. Matthias Kübel, Volkswagen AG UPDATE: How will the system be developed further in the future? What role does Phoenix Contact play in this process as a system supplier? Kübel: We're already able to provide charging currents up to 200 A. It's a very good amount when you consider that we're talking about continuous current here. However, in future we are planning for electric vehicles that ofer a driving range of 500 kilometers and beyond. In order that the batteries of these vehicles can be charged in a short time, the charging currents need to be increased further. This is where Phoenix Contact can support us thanks to their expertise and experience. European bus manufacturers have also shown interest in the CCS and plan to use the CCS charging system for electric city buses. This would be a big breakthrough for the expansion of the charging infrastructure in towns and municipalities as these buses will need charging stations at the terminal stops, which could then also be used by private electric transport. UPDATE: Thank you very much for talking to us. “Interoperability and the further expansion of the CCS charging infrastructure are currently the biggest issues.” the CCS in Europe. The European Automobile Manufacturer's Association, the ACEA, has recommended the CCS as the charging standard for Europe and with the EU directive for alternative fuels, the European Commission has prescribed the CCS as the mandatory charging standard for every fast charging station from 2017. Meanwhile, the CCS is available worldwide from eight charging station manufacturers, including manufacturers in Taiwan and Australia, for example. We expect to add more manufacturers to the list this year.
04 Cover story UPDATE 1|15 UPDATE 1|15 The Volkswagen e-up! can be charged quickly and safely with the Combined Charging System (CCS) A i rm i xture Phoenix Contact of ers components and systems for modern charging technology E-Mobility has crossed the barrier to become an everyday technology. The Combined Charging System is a standard for everyday AC and DC charging applications. As a partner to the automotive industry as well as a supplier of components for the charging infrastructure, Phoenix Contact is optimally positioned in the increasingly progressive market for E-Mobility. Signs for charging electric vehicles have become a familiar sight in many places in our towns and cities. We are even i nding charging stations for battery-powered electric vehicles at rest stops on the German Autobahn. Here travelers can recharge their vehicle's power storage during a 20 to 30 minute stop – pretty much the typical time spent at a rest stop. With the Combined Charging System (CCS), a vehicle is fully operational again even after charging for such a short time. There is therefore no technical impediment to making a long journey in an electric car. This is something that owners of electric vehicles have been able to experience since May 14, 2014 on the stretch of the A9 Autobahn between Munich and Leipzig. There are eight fast charging stations equipped with the Combined Charging System that are positioned along the Autobahn in both directions. However, in order for the German government to reach its target of one million electric vehicles on the road by 2020, an extensive network of these charging stations must be set up along all Autobahns and also in urban areas. The number of generally accessible EV charging stations that are required more or less corresponds to the number of conventional gas stations. These charging stations will not only be located at public parking lots, but also in any location where you might leave your vehicle for a short or long period as part of your daily routine. This includes supermarkets, shopping malls, restaurants, and even hotels. However, the primary locations for drivers of electric vehicles are above all their parking spaces at home and at work. The right charging technology for every requirement There are three dif erent methods for charging an electric car: fast DC charging, conventional AC charging or contactless, inductive charging. From a technical point of view, inductive vehicle charging is relatively complex. A coil with the necessary transreceiver electronics must be present both on the vehicle and at the charging point, i.e., the charging infrastructure. However, this method is very convenient for the vehicle owner, as they simply have to position
UPDATE 1|15 Cover story 05 the receiver coil installed in the car in the immediate proximity of the transmitter coil. We can soon expect to see the i rst cars equipped with this technology in the top price segment. AC charging is the most widely used method at present, as it is also the easiest to implement in the private sector. Due to the relatively low charging power, charging typically takes between i ve and eight hours. Realistically this charging time is feasible and non-critical if your car can be charged overnight when parked at home or during the day at the company parking lot, for example. However, this charging method is problematic for journeys over longer distances when recharging is occasionally necessary. This remains the primary reason why many people decide against an electric vehicle. However, this should no longer be a concern, since DC charging has been developed in order to solve this problem. The charging power transmitted with this method is signii cantly higher, thereby shortening the charging time accordingly. In this case, charging typically takes around half an hour. This is a period of time that can easily be spent shopping or enjoying a short break at a rest stop during a journey. Sophisticated charging technology “under the hood” Although the charging process may seem relatively uncomplicated to the user from the outside, it is simply not possible to compare the charging of a battery-powered car to charging a smartphone. In addition, the power involved is considerably higher. DC charging in Europe reaches up to 200 A. It is not just about achieving the optimum battery charge, but also charging in a way that maximizes the service life of the batteries. However, the crucial factor when charging with high currents is ensuring maximum Nuremberg Berlin Leipzig Munich Charging station next exit – a plausible model for our rest stops
06 Cover story UPDATE 1|15 Integrated into the power grid with Vehicle to Grid Vehicle to Grid – V2G for short – refers to the integration of the ve- hicle into the power grid of the future. The electric vehicle commu- nicates via the charging station with the power grid to which it is connected. Details of the charging process are speciied based on the technical data for the charging station, the availability of energy, and the user's desired mobility. As a result, charging processes can be coupled to the availability of renewable energy, for example. This communication is based on standard ISO/IEC 15118 and can be applied in principle to all forms of charging – whether AC or DC. Data transmission is in ac- cordance with the Powerline HomePlug Green PHY standard. possible safety. To do this, a sophisticated form of communication known as Vehicle to Grid takes place between the charging controller, the communication and control device in the car, and its equivalent in the charging station. In addition, charging is protected by locking the Vehicle Connector in the Vehicle Inlet, thereby preventing the connector from being removed when under load. However, the release of the connector can also be controlled by means of this communication, for example, if the vehicle owner wishes to continue on their way with the battery charged at just 70 percent. CCS – the standard for Europe In order to enable the uniform charging of cars in Europe, one standard has been speciied for the charging system and the charging protocol in the form of a European regulation. Phoenix Contact played a leading role when working together with the German automotive industry on the Combined Charging System (CCS) charging interface. This system allows cars to be charged with DC and AC voltage. A CCS inlet is installed in the electric vehicle which accommodates both an AC and a DC Vehicle Connector and therefore combines both charging methods for use in everyday scenarios. There are a total of three core global markets for which standards for the charging system for electric vehicles have been speciied. Phoenix Contact develops and produces charging connectors and Vehicle Inlets for all international markets and so ofers a comprehensive product portfolio with equivalent quality and safety standards. Helmut Friedrich phoenixcontact.com Phoenix Contact ofers charging systems for E-Mobility in Europe, China, and the USA Charging mode 2 Charging mode 3, case B Charging mode 3, case C Charging mode 4 Type 1/North America Type 2/Europe GB/T standard/China Type 2
UPDATE 1|15 On site 07 Street scene in Nanjing. China seeks to reduce smog pollution through intensive promotion of E-Mobility. Making way for electric vehicles Intensive promotion of E-Mobility in China The Chinese government plans to have ive million registered electric vehicles by 2020. In this way, the country hopes to tackle its looming environmental and transport problems. In order to support this move, Phoenix Contact is creating a subsidiary for E-Mobility. The reason why China is focusing its attention on E-Mobility is clear: the quality of life in Chinese cities is decreasing due to growing smog pollution caused by increasing emissions from conventionally-powered cars. In this case, it is not enough to simply limit the registration of new cars, since it is already clear that there are not enough vehicles compared to the population density. Making way for electric vehicles Electric vehicles present an attractive alternative, especially in Chinese cities where the registration of new cars is regulated by auctions. The license plates for electric vehicles are issued more readily by the authorities and are also less expensive. Furthermore, buyers of electric vehicles in China also receive a subsidy of up to 7200 euros depending on the region. The expansion of the charging infrastructure is also being encouraged. The authorities even plan to impose stringent requirements for the construction of new residential neighborhoods to ensure that residents are adequately supplied by the charging infrastructure. In addition, it is hoped that carpooling with a clear focus on E-Mobility will also reduce strain on traic-plagued inner cities. These types of projects also receive generous state support. GB standard charging connector Only electric vehicles developed and produced in China are subsidized. One such example is the joint venture between BYD Auto Company Limited and Daimler AG which launched the Denza New Energy Vehicle in 2014. The vehicles are sold together with fast charging stations for which Phoenix Contact supplies the DC Vehicle Connectors according to the GB standard. The rapid development of the Chinese E-Mobility market has prompted the Phoenix Contact Group to create another subsidiary in Nanjing. This new company will be responsible for developing and manufacturing products for the Chinese E-Mobility market. Julia Krüger phoenixcontact.com/update
08 Technology UPDATE 1|15 DC charging stations with the EV CC Professional controller make fast charging easy and convenient Smart charging solution Flexible controller for DC fast charging stations The Combined Charging System is more than just a charging connector – communication between the charging station and electric vehicle has also been revolutionized. For DC charging, the relevant charging parameters such as the desired charging current and the maximum battery voltage must be exchanged between both sides. With the EV CC Professional, Phoenix Contact now ofers a powerful controller for DC fast charging stations. Even though the CCS is the European solution for fast charging, there are still only a few manufacturers who are ofering the corresponding systems. This is due to the more stringent function and safety requirements for charging with direct current (DC charging). In the case of DC charging, the power electronics of the charging station are connected directly to the high-voltage battery of the vehicle and the charging parameters that were negotiated with the vehicle must be set exactly. In order to ofer a system which, despite the speciic properties of direct current with its high currents and voltages, corresponds to AC charging in terms of its safety and availability, comprehensive measures were introduced with the development of the CCS. These include, among others, mandatory insulation monitoring, monitoring the temperature of the charging connector, and identifying errors and the corresponding responses to them. Communication between the vehicle and charging station presents a particular challenge. In order to ensure that the solution is also equipped to handle future tasks such as automated identiication and billing processes, a communication protocol has been implemented based on Powerline and TCP/IP. In addition to the reliable transfer of the charging parameters, this also takes data security and data integrity into consideration. Paving the way for CCS System integrators are therefore faced with the challenge of not only consolidating function and safety requirements in compliance with standards, but also being able to respond lexibly to customer requirements. With the EV CC Professional, Phoenix Contact ofers a
UPDATE 1|15 Technology 09 DC charging station for beginners For easy entry into the world of DC charging technology, there is a special electronics board on which V2G (Vehicle to Grid) communication is implemented according to ISO 15118. A CAN master and a visualization panel on which the application runs are connected to the board. These are used to send all relevant data for the DC charging process to the ISO 15118 board. Customers can familiarize themselves with DC charging technology in E-Mobility and create their application. The software that is developed can later be transferred to the EV CC Professional charging controller for use in practical applications. can also be used to control the corresponding charging socket. Manufacturers of charging infrastructure can therefore cover the full range of charging modes used in E-Mobility with a single controller. Thorsten Temme, Dirk Vogel phoenixcontact.com freely programmable controller that has been developed specii cally for the requirements of E-Mobility and the Combined Charging System. The Axiocontrol core, the new PLC series from Phoenix Contact, has been extended with the necessary interfaces and functions for communication with the vehicle and the higher- level control and billing systems. Furthermore, the system integrates additional components of the charging station. The customer can program the user software in the familiar IEC 61131 environment with PC Worx. A small, web-based operator interface can be created using WebVisit or Visu+. Support for common standards Communication with the vehicle is in accordance with the current DIN SPEC 70121 or future ISO/IEC 15118 standards, as well as Powerline HomePlug Green PHY, which is modulated to the control pilot signal of the charging connector. Dei ned function blocks are available for this which software developers can integrate into their application program. These function blocks supply and send the data from and to the vehicle, enabling easy further processing in the application. The developer does not have to deal with the details of communication on the lower layers of the communication protocol. Charging parameters that implement the power electronics in the charging station are derived from communication with the vehicle. Corresponding power electronics modules from various manufacturers can be connected to the system via Ethernet or serial interfaces (CAN, RS485, RS232). Additional components such as power meters, insulation monitors or sensors are also connected to the system in this way. The controller has inputs for monitoring the temperature in the charging connector. The charging station is also equipped with a conventional interface for AC charging; this interface The new DC charging controller – EV CC Professional
10 Solutions for the future UPDATE 1|15 Sustainable E-Mobility Gildemeister energy solutions controls its EV charging stations with a solution from Phoenix Contact Impressive, sustainable concepts can be created by combining E-Mobility with renewable energy and storage solutions. Gildemeister energy solutions uses a solution from Phoenix Contact in its EV charging stations to control and monitor the charging process. It is the l exibility of the ILC small-scale controller in particular that enables easy connection to the downstream databases. “Green driving with green fuels” – in line with this philosophy, Gildemeister energy solutions of ers a solution for E-Mobility in industrial plants and municipalities. The l eet of electric vehicles is part of an overall concept that includes generating renewable energy on site using photovoltaics or wind energy and storing it using vanadium redox l ow storage systems. The entire system at Gildemeister energy solutions is geared towards the continuous and clean supply of energy for self-consumption in the buildings on site and also for the corresponding E-Mobility. This means that when vehicles are not being charged, the renewable energy is used in an alternative way, such as for production lines or for lighting and energy supply in oi ces. This overall concept is attractive not only for public charging points, but also for medium-sized companies that The energy for the EV charging station is generated using solar tracking systems and is stored in large batteries
UPDATE 1|15 Solutions for the future 11 would like to be energy neutral. What makes this concept particularly special is that generated energy is stored locally, which avoids expensive power lines for power transmission, and makes it easier to expand the charging infrastructure. This is particularly advantageous considering the higher charging power and increasing number of simultaneous charging processes expected in the future. The charging stations do not need to be connected to the medium-voltage systems, something which would otherwise be inevitable. The vanadium redox l ow storage system supplies a high level of power for charging on an ad hoc basis and is constantly being recharged with volatile forms of energy, namely solar and wind energy. Various charging standards supported The EV charging station of ers six charging points for dif erent contact systems: Type 2 standard and home receptacle. At another charging station, drivers can charge their electric vehicles with up to 50 kW using DC fast charging technology. The system gets the charging current from the Cellcube power storage system, in which energy is stored locally. Retroi tting for a uniform standard Phoenix Contact was approached in 20 13 to retroi t the existing overall system at Gildemeister energy solutions and equip it with new hardware and software. As part of the project, the charging technology was
12 Solutions for the future UPDATE 1|15 Step power supplies Switch ILC 170 ETH small-scale controller Charging controller and Lock-Release Ril ine relay system Push-in terminal blocks A look inside the control cabinet of the EV charging station: this is where Phoenix Contact is used for E-Mobility
UPDATE 1|15 Solutions for the future 13 also completely replaced. The aim of the retroi tting project was to standardize the technical equipment used in all of the existing charging stations at Gildemeister. The system in Geretsried near Munich was used as a pilot project. Successful implementation, from the initial idea to startup, only took around two months to complete. It was then possible to roll out the new company standard across Europe. Challenge: back-end connection The concept for the charging station hardware and software was developed by Phoenix Contact and adapted to Gildemeister's specii cations. The control cabinets were built and supplied by Hartmann Elektrotechnik in Hamburg. Adapting the communication technology to the existing data infrastructure presented a particular challenge for the experts. The charging technology communicates with an SQL database on the server side using an ILC 171 ETH small-scale controller. Phoenix Contact was responsible for the complete implementation of the charging process. This included developing as well as integrating the energy and information technology. The remit for the experts included, for example, the control and monitoring of the charging processes according to Type 2 and with home receptacles, comparing user data with an on-site SQL database, and creating a website for the technical customer services at Gildemeister energy solutions for dealing with service jobs. Furthermore, Phoenix Contact was responsible for coni guring the electrical design, supplying the control cabinets together with Hartmann, programming and starting up the software, and dei ning the interfaces to the database system. The right turn-key solution Gildemeister energy solutions chose Phoenix Contact because the Blomberg-based company of ered a turn-key solution. Thanks to the variable control system according to IEC 61131 and its specii c libraries, the interfaces could be operated by the customer. Another E-Mobility for major customers: Gildemeister energy solutions Gildemeister energy solutions of ers turn-key solutions for energy management for industrial customers and municipalities. This includes ei ciency analyses for saving energy as well as systems for generating, storing, and using renewable energy. With the SunCarrier solar tracking system, the WindCarrier small wind turbine, and the CellCube power storage solution, innovative and intelligent energy concepts are possible, which deliver green electricity both day and night. Every industrial plant can therefore cover some of its own auxiliary power consumption, without needing to be connected to the grid. Use of the generated energy in the company's electric vehicles is central to this concept. Gildemeister energy solutions operates out of six locations and currently employs around 160 people. energy.gildemeister.com advantage for Gildemeister energy solutions was the extensive product range of ered by the Phoenix Contact Group. In addition to products for E-Mobility, Phoenix Contact also of ers expertise gained from decades of experience in control cabinet installation. ILC controllers, switches, terminal blocks with push-in technology, Step power supplies, Ril ine industrial relays, and EV charging controllers for mode 3 were therefore all incorporated into the turn-key solution. Jens Eickelmann phoenixcontact.com
14 In the spotlight 1996 First Fieldbus Congress on Interbus held in Blomberg 1999 First industry day focu- sing on the automotive industry 2000 Focus on the automotive industry and machine building – under the slogan: Speed, Connectivity, and Safety From i eldbus to Proi cloud A review of 20 years of the Industrial Communication Congress Once again industry experts came together on March 17 and 18, 2015 at Phoenix Contact Electronics in Bad Pyrmont to attend the 20th ICC – this time under the slogan “From i eldbus to Proi cloud”. This marks the perfect occasion to review the history of this industry event. of information about new technologies and developments. 1994 was a milestone year with the German standardization of Interbus according to DIN 19258, followed four years later by international standardization according to EN 50254. It all started back in 1996. The Interbus i eldbus system, originally developed by Phoenix Contact and launched on the market in 1987, had been developed successfully over a period of nine years. The i eldbus system quickly established itself as the standard communication medium in factory automation, especially in the automotive industry. The publication of the protocol led device manufacturers to develop interfaces to make their devices compatible with this important system for sensor/actuator cabling. In 1990, a dozen manufacturers of drive devices came together to form the Drivecom user group in order to dei ne a uniform interface and therefore enable users to l exibly use devices from dif erent manufacturers in the communication network. In 1992 this became the Interbus Club e. V., an intermediary between users and manufacturers that was responsible for the certii cation of Interbus-compatible devices, the coordination of work groups and user groups, and the sharing From the “Fieldbus Congress” … The i rst “Fieldbus Congress” was held in Blomberg in 1996 to provide a platform for dialog between users and manufacturers. Around 350 participants from various dif erent industries came together for the three-day event to share experiences, gain knowledge, present solutions, and visit the accompanying exhibition – and to learn more about Phoenix Contact with a tour of the company's site. The congress became an annual event with the number of participants growing to between 400 and 500. From 1999 onwards, the congress was shortened to a two-day event and the program, which for the previous three years had covered various industries, now focused specii cally on the automotive industry for the i rst time. A clear division was made the following year: the i rst day focused on machine building, the second day on the automotive industry. For many years these industry days formed
UPDATE 1|15 In the spotlight 15 the framework of the Fieldbus Congress, which was always held in Blomberg in September. The visitor center was no longer big enough and the exhibition moved to a large exhibition tent. … to the “Industrial Communication Congress” In 2000, thanks to the visionary approach of the congress, the focus was already on safety and the topics of “Speed, Connectivity, and Safety”. Five years later, the focus also extended to Ethernet and wireless. As a rel ection of this, the event was renamed in 2005: the Fieldbus Congress became the “Industrial Communication Congress (ICC)”, as the event was no longer just about i eldbus systems. Models for integrating Interbus in Proi net were presented as early as 2004; Phoenix Contact's product portfolio had grown to include control technology, software, and display devices. 2004 Proi net in focus development of production automation in the years to come. Move to Bad Pyrmont In 2008, the 13th congress marked another milestone: for the i rst time, the event was not held at Phoenix Contact's headquarters in Blomberg, but moved to Bad Pyrmont, the home of electronics production for the company since 1996. The construction of the Innovation Center Electronics (ICE) provided a large auditorium as well as ample conference rooms and exhibition rooms that of ered plenty of space to host the congress as well as being a prime location close to electronics production. Another fundamental change came i ve years later, this time with respect to the schedule: the ICC was moved from September, which had always clashed with the fall break in Germany, to a date in March. The risky move to change the date after 18 years paid of : the two days devoted to security were soon fully booked. 2013 20 years of the ICC – Happy Birthday! Focus on Industrie 4.0 2015 Event held in March for the i rst time, focus on Safety and Security 2005 From the “Fieldbus Congress” to the “Industrial Communication Congress” (ICC) 2008 Event held in the Innovation Center Electronics (ICE) in Bad Pyrmont for the i rst time, focus on IT-powered Automation Another milestone was also set for safety in 2005 with the certii cation of the Interbus- Safety system by the TÜV Rheinland Group and the BGIA. Increasing focus was given to the safety of people and machinery as well as data security. The introduction of Ethernet in factory automation marked a trend that in 2015 is now well-known as Industrie 4.0 – data consistency, the digital product, and modular, convertible production. Thus the slogan in 2008 for the ICC was “IT-powered Automation”. The introduction of IT as well as the demand for energy ei ciency were to clearly shape the The successful concept of bringing together manufacturers and users, offering an authentic manufacturer environment and demonstrating solutions in real production, as well as engaging professional speakers not only from within Phoenix Contact, but from across the industry, is still what draws people to the event in its 20th year. All that remains to be said is Happy Birthday ICC! Angela Josephs phoenixcontact.com
16 Technology UPDATE 1|15 The new E-bus from the Bozankaya Group has already demonstrated its suitability for everyday use The quiet powerhouse E-Mobility for utility and special-purpose vehicles energy is achieved by the eco-friendly, powerful electric propulsion system. The Sileo's batteries are charged once a day via a Vehicle Inlet from Phoenix Contact. The buses are equipped with their own mobile charger (32 kW/64 A). The charger has a special Vehicle Connector from Phoenix Contact that has been specifically adapted to the requirements of Bozankaya. Hybrid aircraft tugs from Kalmar Motors Some time ago already, many airport companies started to replace diesel-powered vehicles with vehicles using electric motors. The “E-Port An” project at Frankfurt Airport, for example, was awarded as a flagship project by the German federal government. Conventional vehicles cover a distance of many kilometers When it comes to E-Mobility, most people think about vehicles in the private sector. However, in addition to the major automobile manufactures like the Volkswagen Group, BMW, Mercedes, and Ford, manufacturers of utility and special-purpose vehicles are also instrumental in shaping the E-Mobility market. E-Mobility solutions have emerged for virtually all vehicles and means of transport. Two examples of utility vehicles for which Phoenix Contact supplied the charging interface are described below. Sileo electric bus from Bozankaya The Sileo electric bus is a German/Turkish joint production by the Bozankaya Group. With its design concept and battery drive, this vehicle from Sileo GmbH represents the future of public transport. At the heart of the drive is a battery system with a capacity of 200 kilowatt hours. The energy is stored in 300 individually supervised and controlled battery cells mounted on the roof of the vehicle. The power from these drives two electric motors, one at each side of the rear axle. The electric bus has a driving range of over 200 kilometers. Its long range and above-average recuperation of electric
UPDATE 1|15 Technology 17 on airfields. Aircraft tugs have become especially important when airports want to operate in an environmentally-friendly way as they enable efficient and almost emission- free aircraft towing on the airfield. The tractors manufactured by the Swedish company Kalmar Motor AB operate without towbars and are driven electrically 95 percent of the time. They can tow every aircraft up to the Airbus A380, and even offer driverless operation. The built-in diesel engine is only used to charge the batteries if required. During towing, the moving mass of the aircraft is transformed into energy and used to charge the batteries. For the tractors, Kalmar uses the latest generation of lithium-ion batteries, which can be charged via a vehicle charging connector from Phoenix Contact. The charging system allows high-capacity batteries to be charged even during short stops. Julia Krüger phoenixcontact.com The new hybrid aircraft tugs from Kalmar Motors are equipped with a charging interface from Phoenix Contact Combined Charging System (CCS) in cars Phoenix Contact E-Mobility GmbH has worked together with automobile manufacturers Audi, BMW, Daimler, Opel, Porsche, and Volkswagen to develop the Combined Charging System (CCS) for fast vehicle charging. This system supports charging of electric vehicles with direct and alternating current as both AC and DC Vehicle Connectors i t in the inlets. The interface is therefore suitable for charging all kinds of electric vehicles, including bikes and hybrid vehicles. Following the standardization of the charging interface, the CCS Vehicle Inlet from Phoenix Contact E-Mobility was used in the i rst fully electric vehicle from Volkswagen – the VW e-up!. This was followed half a year later by the VW e-Golf with CCS Vehicle Inlet.
18 On site UPDATE 1|15 Pooling resources Network of emergency power generators creates a virtual power plant Network operator Tennet uses a virtual network of emergency power generators to respond flexibly and rapidly to fluctuations. The NL Noodvermogenpool emergency power pool is controlled using a solution from Phoenix Contact. A series of Dutch companies which have one or more emergency power generators have joined together to form the NL Noodvermogenpool. The idea came from Maarten Schaareman, who is currently also the director of the NL Noodvermogenpool. He established the company in 2011 in consultation with Tennet in order to support the Dutch network operator in ensuring a reliable national transport network. In the Netherlands, statutory regulations guarantee the stability of the power grid. In order to keep the grid in a steady state, the network operator must act with foresight. Tennet forecasts usage for seconds as well as longer periods of time. If unexpected stability problems arise in the national transport network, the generators are available in reserve. The companies are compensated for making their emergency power generators available and for their occasional usage when required, which essentially means that the existing generator pays for itself. Control concept designed by system integrator However, before the emergency power generators of the individual partners are included in the pool, their operational reliability is tested by system integrator Unica. They are then connected using automation technology. The control system was designed by Unica, which employs around 1600 people at 14 sites across the Netherlands. The company specializes in green technology and power supply. This means that many major projects such as office buildings, hospitals, The emergency power generator of water supplier Vitens is part of the NL Noodvermogen- pool
UPDATE 1|15 On site 19 stadiums, industrial production plants or wastewater treatment plants are designed to be as environmentally friendly as possible. Unica also integrated the emergency power generators of the largest supplier of drinking water in the Netherlands, Vitens, into the NL Noodvermogenpool. be scaled by adding or removing generators. This type of virtual power plant can therefore respond immediately to mains fluctuations and also compensate significant deviations that occur when energy is fed in from renewable power generators. Fast startup and fine scaling Server sends request signal to small-scale controllers There are currently around 100 emergency power generators in the NL Noodvermogenpool. This corresponds to an installed capacity of around 55 MW in continuous operation or 61 MW peak power. The solution results in a power plant that is distributed over a large area, which can be started up quickly because the individual generators all have a relatively short startup time. For example, a 1 MW generator is usually at full power in under five minutes. Furthermore, the level of power output can be finely regulated as the amount of energy can When required, Tennet requests emergency supply by calling the team at NL Noodvermogenpool which is available round the clock. The person who handles the call is told how much energy needs to be provided in the next five minutes. The request is then entered in a web portal and all subsequent steps are carried out automatically. A rotation worksheet linked to a database determines which emergency power generators are available. Not all of the generators in the pool are available at all times. For example, generators are not used if they are located
20 On site UPDATE 1|15 close to residential buildings and their operation would create a lot of noise. The rotation worksheet therefore determines at what time of the day mains operation is possible. In addition, priority is given to the generators that have the fewest operating hours. This ensures that all generators in the pool are used equally. Having determined which emergency power generators are required so that the requested energy can be generated, the server installed in the control room sends a request signal to all the relevant generators. The generators are equipped with an ILC 151 GSM/GPRS small- scale controller from Phoenix Contact. Since the controller has an integrated GSM/GPRS modem, the device can be reached via the mobile phone network. In addition to wireless communication, there is also a wired Ethernet connection which ensures that the PLC always receives the necessary command. Small-scale controller ensures reliable startup The controller processes the request signal and first of all switches on an audible and optical warning system that is installed locally. This signals that the generator will start up in 30 seconds. Personnel in the vicinity therefore have enough time to leave the room or to put The ILC 151 GSM/GPRS small-scale controller with integrated GSM/GPRS modem responds to requests and sends status information to the control room VHPready industrial standard Phoenix Contact is working with partners from industry, energy, and research on a standard for networking distributed energy generators. The VHPready (Virtual Heat & Power) standard is the basis for virtual power plants in which volatile renewable energy generators are networked. vhpready.com on ear protectors. The controller then receives the data from the emergency power generator and informs the system that the generator has started up. The same is true if a fault occurs. In this case the server in the control room seeks out the next available generator. In addition, the relevant company is automatically notified by text message or e-mail if their emergency power generators are requested, have a fault or if there are connection problems. All generators requested by the server start up within 30 seconds. The nominal power is available after ten minutes. Temporary needs can therefore be covered quickly. As soon as the transport network is returned to a steady state after 15 to 60 minutes, Tennet logs out the emergency power generators and the server shuts them down. The generators that were used then move to the bottom of the priority list. Thanks to this solution, network operators always have quick access to power reserves, thereby ensuring the level of network performance that is required by law. Industrial end consumers benefit from more stable production processes and consequently better product quality. Michael Gulsch phoenixcontact.com
22 In the spotlight UPDATE 1|15 Dedicated to standardization Roland Bent starts 2015 as the new Chairman of the DKE steering committee At the start of the year, Roland Bent, Executive Vice President Marketing and Development at Phoenix Contact, took over as Chairman of the DKE steering committee (Deutsche Kommission Elektrotechnik Elektronik Informationstechnik - German Commission for Electrical, Electronic & Information Technologies). The DKE is ailiated with the VDE (Verband der Elektrotechnik und Elektronik - German Association for Electrical, Electronic, and Information Technologies) and develops standards and safety regulations for these disciplines. It represents German interests in the European Committee for Electrotechnical Standardization (CENELEC) and in the International Electrotechnical Commission (IEC). Mr Bent succeeds the previous Chairman Wolfgang Hoheinz. The steering committee of the DKE comprises up to 37 leading economists, scientists, and state administrators and is the highest decision- making body within the DKE with regard to standardization policies and the organization and performance of standardization activities. As Chairman, Roland Bent will represent the DKE both internally and externally. He will inluence key decisions in terms of organization, management, and personnel and will chair the committee from 2015 to 2018. Mr Bent has been involved in electrotechnical standardization for over 20 years. From the top loor to the shop loor Eplan, Rittal, and Phoenix Contact present consistently digitized production at the Hannover Messe Roland Bent, Executive Vice President Marketing and Development Eplan, Rittal, and Phoenix Contact will jointly present the complete vertical integration of data in the engineering and production process at the Hannover Messe 2015. Visitors to the trade fair can ind out irst-hand how product data is generated, used for the creation of virtual prototypes, and forwarded to the production stage via standardized interfaces. At their booth in Hall 8, the “Smart Engineering and Production 4.0” technology network will demonstrate the consistent automated process that leads from the digital item through engineering to production: data from a complete, virtual product description lows from the development stage to the manufacturing process via standardized interfaces. “We use the example of a real, highly automated manufacturing process for production batch 1 to illustrate the concrete potential of consistent digitization as well as the complete integration of data across areas and systems,” explains Roland Bent, Executive Vice President at Phoenix Contact.