Cases & enclosures
Reduce time and costs foR contRol panel manufactuRing
complex, the trading environment is extremely competitive, and customers naturally want to keep their costs to a minimum. The pressures (and costs) start from the
E
moment a manufacturer’s estimating engineers receive details of a new project. A typical specification has more than 300 pages. Delivering a control panel build takes a substantial number of man-hours, resources and again, of course, costs. Simply preparing engineering and schematic drawings for client approval might involve: incorporating client changes; project adjustments; close co-ordination between design and manufacturing teams; and using standard products wherever possible. Key challenges for the next step – the
manufacturing phase - include managing resources within tight timescales. There is no doubt that rising demand in
the sector is being matched by a trend for shorter lead times. Meanwhile, the sector is experiencing long-term major shortages in skilled workers so recruitment has become more problematic, particularly for short-term contracts on major projects. The most time-intensive phase of a typical control panel is usually wiring (preparing
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lectrical control manufacturers are currently being placed under considerable pressure. Projects are becoming more
wires, reading drawings for routing points and termination) which takes up around half the time. Design and engineering take up around 10 per cent of the time. In addition, there are further modifications including the number of cut-outs and the holes for door fixings to be accounted for. There are two ways in which Rittal can
considerably reduce the manufacturing costs of a control panel. It can optimise the engineering and schematic design phase using EPLAN software. It can also automate the processing of wires ready for installation.
EPLAN
Wiring control cabinets will always remain a job for skilled and experienced staff, but it can be made easier. If the control panel is designed with EPLAN Pro Panel, the engineer can visualise the route of each individual wire in 3D, to optimise the pathway and for easy installation. It also ensures that the trunking capacity is not exceeded and that the correct cable separation takes place. EPLAN Pro Panel easily and automatically
generates lists that provide all the necessary information to engineer, including the routing, end points, cable designation, as well as the size and colour of each wire. The lists make wiring easier and faster and significantly
reduce the chance of errors. Another major benefit is uniformity. The
detailed wiring lists ensure that two or more of the same control cabinets have identical wiring, making life a lot easier during later modifications or fault-finding. EPLAN Pro Panel with EPLAN Smart
Wiring also allows users to see the wires during wiring on their laptop or tablet, while their progress is mapped, tracked and displayed in real time. This means it is virtually impossible to miss wires, even if a wiring job starts with one person and another finishes it. EPLAN P8 can create 3D layouts of an
electrical system in Pro Panel. This virtual prototype then forms the basis for further project work. The selected parts can be automatically transferred to an ERP system, dramatically cutting the time spent on materials procurement. The 3D construction planning also shows
any potential difficulties that could arise during production. For example, if a component on the mounting plate collides with the enclosure door, it can be detected at this early stage. This means that any corrections can be made during the planning stage and not in the workshop, which cuts production times and costs significantly.
February 2021 Instrumentation Monthly
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