The hybrid storage system consists of a kinetic and an electrochemical energy storage system, which are connected via a common DC bus link. This interconnection makes it possible to use a common grid-sided inverter and thus reduce the number of components.

The kinetic storage is an outer rotor design specifically developed at the IMS for the use in the factory. It consists of a CFRP rotor that rotates at speeds of up to 15,000 rpm to store energy. The energy is converted via a permanent magnet synchronous motor and fed into the DC bus of the hybrid system via a modern 3-level inverter (switching frequency: 16 kHz). The rotor is actively magnetically levitated to minimize maintenance and wear. In addition, the contact-less bearing enables operation in vacuum, which in turn minimizes air friction losses. The described storage system is characterized by its high cycle life and electrical power. The electrochemical storage is a lithium-ion battery from the manufacturer Akasol AG. The battery is characterized by a high energy density and is integrated into the DC bus via a DC/DC converter.

During operation, the requested electrical power must be split between the two storage systems. Appropriate algorithms to determine this spilt are currently the subject of research at IMS and can be tested on the real hybrid system. The hybrid storage system can pursue a wide variety of goals in the factory to generate added value. Particularly noteworthy in the industrial context are peak shaving, load smoothing, the island grid capability and the reduction of forecast deviations in the load prediction. For this purpose, the storage system is fully connected to the factory’s energy management via an industrial controller and exchanges high-frequency information.