DC Integration and Real-Time Optimization Break Through Traditional Energy Management Bottlenecks
Schaltbau Group, a German industrial solutions provider, recently showcased the practical results of integrating DC infrastructure with its smart Energy Management System (EMS) at its NExT Factory. This system not only enables real-time monitoring of energy usage but also actively optimizes energy distribution by integrating energy generation, storage, building systems, and charging infrastructure. The approach effectively reduces operational costs and enhances overall energy resilience.
Traditional energy management systems often only provide monitoring capabilities, struggling to address grid fluctuations or sudden demand spikes. Schaltbau’s integrated solution, however, uses a single intelligent platform to enable real-time control and optimization of energy use. The company states that this model has been validated within the NExT Factory, successfully reducing energy waste and advancing sustainability goals.
DC infrastructure plays a key role in this solution. Compared to conventional AC systems, DC systems minimize energy loss during AC-DC conversion, making them particularly suitable for applications such as solar power generation, battery storage, and electric vehicle charging. Data from the NExT Factory demonstrates that the DC integration solution can improve energy efficiency by 15% to 20% while reducing carbon emissions by over 10%. These results have attracted the attention of multiple European manufacturers and charging station operators, with some companies already evaluating the adoption of similar systems.
AI-Driven Predictive Analytics Pave the Way for Autonomous Energy Management
Schaltbau emphasizes that future energy management will further integrate artificial intelligence (AI) to transform EMS from passive monitoring into an active decision-making platform through predictive analytics and autonomous optimization. For example, AI can adjust energy distribution in advance based on historical usage patterns, weather forecasts, and production schedules, avoiding high electricity costs during peak periods.
The NExT Factory has already deployed initial AI modules, with plans to achieve full autonomous optimization by 2027. However, AI integration still faces technical challenges, including model accuracy, explainability, and the complexity of industrial environments. Industry experts note that AI misjudgments in complex industrial settings could lead to energy dispatch errors, potentially impacting operational efficiency. Additionally, data privacy and cybersecurity remain key considerations for businesses adopting AI-driven EMS.
Schaltbau states that it is collaborating with partners to develop more reliable algorithms and strengthen system protection mechanisms to ensure the stable operation of AI-driven energy management systems in industrial environments.
EV Engineering Conference Highlights Energy Management Innovations
To promote the application of smart energy management, Schaltbau will participate in the 2026 Virtual Conference on EV Engineering from September 14 to 17, showcasing real-world cases from the NExT Factory. The conference covers all aspects of the EV supply chain, including motor design, battery systems, thermal management, and circuit protection, and is expected to attract over 5,000 engineers and industry decision-makers from around the world.
During the conference, Schaltbau will present a technical report detailing the implementation of DC integration and AI optimization, while also inviting partner companies to share their adoption experiences. Organizers note that these discussions will help accelerate the adoption of smart energy management in manufacturing and charging infrastructure, thereby improving the overall efficiency of the EV ecosystem.
As global energy transition accelerates, the role of smart energy management systems becomes increasingly critical. The proven results from Schaltbau’s NExT Factory not only provide businesses with viable energy solutions but also offer policymakers a reference for decision-making. The European Union has recently prioritized industrial energy efficiency as part of its green transition, with expectations of increased funding and regulatory support for related technologies. Industry analysts predict that by 2030, the global EMS market will exceed $120 billion, with DC integration and AI optimization serving as the primary growth drivers.
