When it comes to electromobility, a discussion about the associated charging infrastructure is usually not far away. Expectations are often based on the goal of achieving as little or no loss of comfort as possible compared to the usual status quo with combustion vehicles. In order to meet this requirement, the automotive industry is working flat out to enable particularly fast charging of electric vehicles, i.e. charging with the highest possible electrical power. In return, the industry is demanding that either the state or other companies (hotels, restaurants, industry & commerce, ...) provide the charging infrastructure. However, the fact that the necessary investments are considerable is all too often ignored. Particularly in existing buildings, neither the connected loads nor the electrical infrastructure are designed to supply additional large consumers with high simultaneity. Although intelligent control technology is theoretically available, it is also associated with high costs and additional installation and maintenance work.
The requirement to be able to charge at almost any location as quickly as possible, i.e. with high power, is therefore potentially becoming an obstacle to the further spread of electromobility. Even a charging capacity of just 22 kW per charging point quickly pushes the electric system to its technical limits - particularly in existing industrial buildings - especially if several charging points are to be installed.
Assuming that around 20 charging points are already available at a site with around 150 employees, this results in a theoretical maximum load of 440 kW, which exceeds the usual connection values even for newer buildings. As a result, a complex load management system would have to be installed that balances the power distribution with the current capacities and, if possible, includes the local generation from PV systems that is frequently available today. After all, vehicles should preferably be refueled with real green electricity and not just electricity that has been colored on the balance sheet. As a 22 kW charging point, including the associated wiring, protection and installation work, often costs several thousand euros, this quickly results in a necessary investment in the six-figure euro range for the industrial company, including the necessary load management system.
WS therefore chooses a different approach at its headquarters in Renningen, which is based on the following key premises:
The required daily charging energy of up to 20 kWh per vehicle, based on the assumption of a maximum distance of approx. 100 km per day, can be achieved over a standing time of nine hours with a continuous charging power of 2.2 kW. On the connection side, special earthed sockets designed for continuous load are easily suitable for this. Such sockets can be installed relatively quickly in existing parking areas. Corresponding supply lines are fused separately in the sub-distributor and, depending on the objective, can be activated permanently or time-controlled using very simple means. Due to the comparatively low theoretical maximum total load of 20 * 2.2 kW = 44 kW, there is no need for a dedicated load management system. The total load is very likely to be less than the remaining surplus generation from the local PV systems. The need for re-parking of vehicles during the workday, which might be necessary with a few charging points with higher power, is completely eliminated. The existing electrical system also offers reserves for further expansion with low-power charging points in the future. If fast charging is still necessary in individual cases, reference is made to external charging infrastructure. The investment required for implementation for WS in the concept presented amounts to significantly less than 10% of the alternative proposals with higher charging capacities, with approximately the same target achievement, and can therefore be easily financed from own funds.
The example presented here impressively demonstrates that a problem-adequate approach is indispensable, particularly in the area of electrical energy supply. The investments required for increasing electrification are considerable, especially in existing buildings, and can hardly be realistically implemented. However, with intelligent concepts which, in addition to the technical conditions, also include a precise limitation of the objectives pursued in each case, high costs can often be avoided without significantly reducing the achievement of objectives. Implementation is then easily possible without subsidies.
However, as unbiased and non-profit-driven external advice is particularly difficult to find in this area, entrepreneurs should endeavor to formulate clear objectives and demand implementation within previously defined framework conditions.
There was a lot to celebrate at the WS Summer Party 2024. Around 250 guests spent a thoroughly successful day in Renningen in the best weather and found out about the many new developments in the WS Group. Good food and a cold drink or two ensured a great atmosphere and fond memories.
Several high-ranking delegations from China visited WS in Renningen to find out about the best industrial burner technology available. The focus of the visit was on the low-emission and efficient heating of electric conveyor belt systems. Due to the increasing production of electric vehicles, this market segment is currently experiencing an upswing, particularly in Asia.
With the help of a new electrolyser and surplus electricity from its own PV systems with a capacity of over 400 kWp, WS will supply the laboratories in Renningen with green hydrogen in future. Following the installation of the electrolyser at the end of 2023, the storage and pipeline infrastructure is now also fully operational.
Rexnord Kette GmbH and WS have successfully modernized a belt furnace, reducing the furnace's CO2 emissions by 35%. In addition to new burners with maximum energy efficiency, the optimization of the operating mode also contributes to the CO2 reduction.
Baden-Württemberg's Prime Minsiter Winfried Kretschmann visits WS in Renningen to find out about activities in the field of hydrogen. In addition to the production of green hydrogen from biogas and decentralized ammonia cracking, the high-ranking visit also focuses on the highly efficient and low-emission industrial burners manufactured by WS.
The new research field of thermal process technology is dedicated to the goal of defossilizing high-temperature processes above 1,000 °C. While some processes are flexible enough to be heated with renewable electricity, climate-neutral fuels will be necessary for many applications in the future.
