The German Research Institute Fraunhofer IWU presents the ESiP Analyzer – an analysis tool for energy storage applications in production (ESiP). The tool enables technical and economic evaluation of potential uses for energy storage systems in factories. Its goal is to identify energy storage opportunities with minimal effort and to simplify the design and integration of storage solutions. The ESiP Analyzer focuses on two key areas: reducing power peaks at both the machine and factory levels, and enabling intermediate storage of renewable energy. 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.
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.
Source: iwd/IWU
