Controlled Energy Storage System for Peak Shaving and Power-Failure Bridging in Servo Drive Systems

Frederic Blank; Stephan Beineke

doi:10.24867/36WS022610

Selected Research Articles

Vol. 41 No. 10 (2026): Proceedings of the Faculty of Technical Sciences

Controlled Energy Storage System for Peak Shaving and Power-Failure Bridging in Servo Drive Systems

Frederic Blank
Stephan Beineke

36WS022610.pdf

DOI:: https://doi.org/10.24867/36WS022610
Submitted: October 15, 2026
Published: 2026-10-16

Abstract

Dynamic servo drive systems are characterized by fluctuating power demands and increasing
requirements for supply reliability. This paper presents a controlled electrical energy storage system and its
application in two industrial servo-drive environments. The system combines a bidirectional DC/DC converter, an
electrolytic capacitor module, and a control concept based on voltage droop curves and state-of-charge control. It
is designed for sub-millisecond response times, high transient power capability, and operation without real-time
communication. The first application addresses power-failure bridging in a high-performance injection molding
machine. The second application addresses peak-power reduction in an industrial DC grid supplying CNC
woodworking machines and robots. Optimized control for the active infeed converter and the energy storage system
enables peak-power reduction of more than 30%.

References

[1] BIHK, “Energiewende im Strommarkt – Versorgungsqualität,” IHK in Bayern, Munich, Germany, 2017.
[2] A. Sauer, Ed., Die Gleichstromfabrik. Munich, Germany: Carl Hanser Verlag, 2020.
[3] F. Blank, M. Hausammann, and S. Beineke, “Fast reacting 300 kW energy storage for power failure bridging in injection molding machines,” in Proc. 26th European Conf. Power Electronics and Applications (EPE’24 ECCE Europe), 2024.
[4] F. Blank and S. Riethmüller, “Peak power reduction of drive systems in an industrial DC grid,” ETG-Fachbericht 172, Electromechanical Drive Systems Conference, Vienna, Austria, Nov. 2023, pp. 195–199.
[5] K. Tytelmaier, O. Husev, O. Veligorskyi, and R. Yershov, “A review of non-isolated bidirectional DC-DC converters for energy storage systems,” in Proc. YSF, Kharkiv, Ukraine, 2016, pp. 22–28.
[6] A. Rufer, D. Hotellier, and P. Barrade, “A supercapacitor-based energy storage substation for voltage compensation in weak transportation networks,” IEEE Trans. Power Del., vol. 19, no. 2, Apr. 2004.
[7] ZVEI, Open DC Alliance, and DC-INDUSTRIE2 Consortium, “System concept DC-INDUSTRIE2,” Feb. 2, 2024.
[8] L. Ott, M. Schulz, B. Wunder, and M. Maerz, “Investigation of stability issues in droop-controlled DC micro-grids with intermediate bus architecture,” in Proc. PCIM Europe, Nuremberg, Germany, 2019.
[9] H. Borcherding, J. Austermann, T. Kuhlmann, B. Weis, and A. Leonide, “Concepts for a DC network in industrial production,” in Proc. IEEE 2nd Int. Conf. DC Microgrids, Nuremberg, Germany, 2017, pp. 227–234.
[10] K. Askan, M. Bartonek, and K. Weichselbaum, “Power module for low-voltage DC hybrid circuit breaker,” in Proc. IEEE 3rd Int. Conf. DC Microgrids, Matsue, Japan, 2019.
[11] S. Warkentin, S. Puls, S. Riethmüller, F. Blank, and H. Borcherding, “Measured advantages of a production plant with DC grid in terms of energy efficiency, peak power reduction and power quality,” in Proc. PCIM Europe, Nuremberg, Germany, 2023, pp. 1–7.

[1] [1] BIHK, “Energiewende im Strommarkt – Versorgungsqualität,” IHK in Bayern, Munich, Germany, 2017.

[2] [2] A. Sauer, Ed., Die Gleichstromfabrik. Munich, Germany: Carl Hanser Verlag, 2020.

[3] [3] F. Blank, M. Hausammann, and S. Beineke, “Fast reacting 300 kW energy storage for power failure bridging in injection molding machines,” in Proc. 26th European Conf. Power Electronics and Applications (EPE’24 ECCE Europe), 2024.

[4] [4] F. Blank and S. Riethmüller, “Peak power reduction of drive systems in an industrial DC grid,” ETG-Fachbericht 172, Electromechanical Drive Systems Conference, Vienna, Austria, Nov. 2023, pp. 195–199.

[5] [5] K. Tytelmaier, O. Husev, O. Veligorskyi, and R. Yershov, “A review of non-isolated bidirectional DC-DC converters for energy storage systems,” in Proc. YSF, Kharkiv, Ukraine, 2016, pp. 22–28.

[6] [6] A. Rufer, D. Hotellier, and P. Barrade, “A supercapacitor-based energy storage substation for voltage compensation in weak transportation networks,” IEEE Trans. Power Del., vol. 19, no. 2, Apr. 2004.

[7] [7] ZVEI, Open DC Alliance, and DC-INDUSTRIE2 Consortium, “System concept DC-INDUSTRIE2,” Feb. 2, 2024.

[8] [8] L. Ott, M. Schulz, B. Wunder, and M. Maerz, “Investigation of stability issues in droop-controlled DC micro-grids with intermediate bus architecture,” in Proc. PCIM Europe, Nuremberg, Germany, 2019.

[9] [9] H. Borcherding, J. Austermann, T. Kuhlmann, B. Weis, and A. Leonide, “Concepts for a DC network in industrial production,” in Proc. IEEE 2nd Int. Conf. DC Microgrids, Nuremberg, Germany, 2017, pp. 227–234.

[10] [10] K. Askan, M. Bartonek, and K. Weichselbaum, “Power module for low-voltage DC hybrid circuit breaker,” in Proc. IEEE 3rd Int. Conf. DC Microgrids, Matsue, Japan, 2019.

[11] [11] S. Warkentin, S. Puls, S. Riethmüller, F. Blank, and H. Borcherding, “Measured advantages of a production plant with DC grid in terms of energy efficiency, peak power reduction and power quality,” in Proc. PCIM Europe, Nuremberg, Germany, 2023, pp. 1–7.