Green energy Battery storage requires reliable connectivity solutions

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Wuxi InfiMotion Technology Co., Ltd.

For a stable grid based on green energy, battery storage is indispensable. These complex storage systems require a great deal of expertise. Lapp, as an expert in connectivity solutions, offers companies a comprehensive service, from consulting to the delivery of cables, connection components, and prefabricated systems.

In the realm of photovoltaics, there is a recurring concern: "What do we do when the sun isn't shining?" The transition to renewable energy sources introduces a new challenge in ensuring reliable and timely energy supply. Energy Storage Systems (ESS) are one solution because they help manage the fluctuations in supply and demand, enhance the reliability of the energy infrastructure, and offer efficient solutions for both energy providers and consumers. These systems store excess energy generated during peak sunlight hours and release it during periods of low solar output, thus stabilizing the grid and ensuring a continuous energy supply.

Thanks to Energy Storage Systems (ESS), energy from renewable sources becomes continuously usable by storing excess energy, such as solar power generated during the day, in an energy storage system. If a household produces electricity through solar panels, an interconnected ESS can store this energy in a battery and provide it as needed. For instance, if the household owns an electric vehicle, it could be charged overnight using this stored energy. This not only maximizes the use of generated solar energy but also enhances the overall efficiency and convenience of energy consumption at home.

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By 2040, 10,000 gigawatt-hours are required

Clean electricity is becoming increasingly relevant in all areas of life, both private and industrial, due to climate protection efforts. Consequently, the demand for electricity storage is also rising. However, to meet this future demand and achieve climate objectives, large storage capacities need to be established. According to the International Energy Agency (IEA), the world needs 10,000 gigawatt-hours of storage capacity by the year 2040. This amount of energy is equivalent to the amount needed to power approximately 2.86 million households for a year. To achieve this, significant investment in energy storage technologies and infrastructures will be essential, along with supportive policies to foster the development and integration of these systems into the energy grid.

There is much to consider with connection technology

Therefore, the number of energy storage systems must be increased accordingly. "Anyone who produces energy storage systems quickly realizes that there are many aspects to consider—especially when it comes to connection technology," says John Nijhuis, Project Manager Benelux and ESS expert at Lapp. The manufacturer is a leading expert in integrated solutions and branded products in the field of cable and connection technology.

A customer segment in the Netherlands manufactures the basic structures of storage systems in containers, which they later send to battery manufacturers for further equipping. In this basic setup, everything must fit—including the cable installation that takes place here. However, this is not so simple. "On one hand, there are various solutions for different usage scenarios,” says John Nijhuis. “So I have to ask myself, which cable has the necessary electrical properties for my specific application, and which components can I connect it with?” Additionally, there are corresponding certification processes that must be carried out correctly, as well as fire safety requirements. "Our customers are experts in storage systems, but not in the complex connection technology behind them," explains John Nijhuis. Thus, ESS manufacturers are increasingly asking Lapp for support.

It starts with an inventory

This support begins well before the delivery of cables. To understand what a manufacturer needs for their ESS project, an inventory assessment is necessary. "In the pre-project phase, we make contact with various customer departments relevant to production," explains Yooshin Kim, Lapp expert for energy storage systems and Sales Representative in Korea, who oversees one of the key ESS target markets in the APAC region. Typically, discussions start with the R&D department and the design team about specific requirements, according to Yooshin Kim. It needs to be determined where components such as the battery or battery management systems will be placed in the ESS container. From this, it can be concluded which cables and connection systems are required and, accordingly, what certifications they must have.

When the ESS market started to gain momentum, there simply were no suitable connection solutions for these systems available.

Yooshin Kim, Lapp-expert for energy storage systems and Sales Representative in Korea

Lapp Korea developed the first special cable for ESS

"When the ESS market started to pick up, there simply were no suitable connection solutions for these systems," says Yooshin Kim. Consequently, a new cable concept was necessary. Lapp has been monitoring developments in energy storage solutions and has considered potential connection solutions. It was clear that appropriate cables needed to be particularly fire-resistant, since batteries inherently pose a fire risk, meaning that the cables should not facilitate the spread of fire.

The experts at Lapp Korea developed the first special cable for energy storage systems—the Ölflex DC ESS SC U—for connecting the power management system with the battery. It is particularly fire-resistant and also highly flexible, making it adaptable to the diverse conditions of ESS containers and easy to install. This cable is now used globally by the specialist.

We know that customers, in addition to high quality standards, require two main things from us: firstly, the most cost-effective solution possible, and secondly, fast delivery.

John Nijhuis, Project Manager Benelux and ESS-expert at Lapp

Customer needs at the center

However, the specialist doesn’t just provide a special cable, but also prioritizes the broader needs of their customers. "We know that customers, besides high-quality standards, primarily need two things from us: firstly, a cost-effective solution and secondly, quick delivery," says John Nijhuis. To minimize the effort for customers throughout the entire process, the specialist therefore relies on pre-assembled connection solutions from the Ölflex-Connect system. Customers receive ready-made cable assemblies that they only need to install at the designated spots in the ESS containers. This approach not only streamlines installation but also significantly reduces the potential for errors and labor costs associated with manual cable assembly and installation.

In a standard ESS system, depending on the purpose, additional Lapp cables might be used. Apart from the mentioned Ölflex DC ESS SC U, which is used for connecting the power management system with the battery, other cables such as Ölflex Classic 110, Ölflex 191, and Ölflex TRAY 6111 are utilized for the power supply of various control systems. For data transmission, cables like Unitronic LiYCY (TP), Unitronic BUS CAN, and BUS LD are employed. For Ethernet connections, Etherline Cat.6A is suitable. These diverse options from Lapp ensure that all electrical connectivity needs within an ESS are met with high efficiency and reliability, tailored to the specific operational requirements and environmental conditions of the installation.

Complete solutions as a success factor for the energy transition

The combination of products and services, from consultancy to pre-assembly, positions the specialist as a dependable partner for manufacturers of ESS systems. Lapp supports these manufacturers from the initial planning stages, helping them select the appropriate cables for the specific needs within the ESS container. Their portfolio offers a comprehensive range of connection solutions. Moreover, manufacturers save time with custom-made cable harnesses that are delivered ready for installation. They simply need to be placed in the correct location. This streamlined process not only enhances efficiency but also reduces the potential for installation errors, ensuring a higher level of reliability and system performance.

A success for the energy transition

Such complete solutions not only make the work of battery storage manufacturers easier but also directly contribute to the success of their solutions. When storage solutions are successfully produced and utilized, it signifies a win for the energy transition and the planet. The battery storage systems store generated green electricity, making it available on demand. Thus, the connection solutions offered by the specialist enable the use of clean solar power, for instance, for charging one's electric vehicle—even when the sun isn't shining. This ensures a sustainable and efficient use of renewable energy resources, further supporting the global shift towards a greener, more sustainable energy landscape.