Industrial


The evolution of the industrial control cabinet in the IIoT era


By Rodrigue Mao, head of product management, Distrelec T


he humble control cabinet is a stalwart of any industrial machinery installation. Initially used to house a few relays, fuses, switchgear, and simple controllers, cabinets are experiencing transformational changes.


With the advent of the IIoT, Industry 4.0 and other operational effectiveness improvements, control cabinets are the go-to locations for all the new automation components and systems. However, the machinery space required often exceeds that available. With floor space at a premium, this opens the door to several technological advancements to make the most of fixed cabinet space.


The changing world of industrial control


Modern manufacturing processes are becoming increasingly automated, with Operational Technology (OT) at the heart of this. Production processes routinely use real-time vision processing systems and machine learning neural networks to optimise throughput and asset utilisation. Robots and collaborative robot usage are also commonplace, increasing the technology needing deployment.


Factory floor space: a scarce resource


While the operational efficiency improvements of IIoT and OT can yield significant benefits, they create implementation challenges for plant management. Floor space is always at a premium, with the priority on accommodating production assets. However, what about control equipment? Previously, each machinery item was typically allocated space for a single control cabinet. IIoT installations depend heavily on electronic systems, sensors and actuators. Cabinet and control panel designers now find themselves accommodating vision and image processing, predictive maintenance systems, networking switches and power supplies. Power conversion modules, motor drives, process logic controllers and electrical switchgear also need safely accommodating.


16 April 2022


A key trend currently gathering momentum is digital twins. Essentially, these replicate a physical production line. In addition to monitoring plant performance, they provide a digital platform for simulating and modelling different production techniques and scenarios. More technology places further pressure on cabinet and panel space, highlighting the need for a structured approach.


Control cabinet challenges For industrial system architects, finding space for another item of control equipment is only one challenge. Designing a new panel requires a careful review of the types and numbers of devices to be included. Is there a logical grouping to them regarding their function or physical size? What about connectivity to other modules and controllers? Perhaps locating specific parts adjacent to each other is beneficial for reducing cabling complexity. Also, grouping devices of the same height profile helps optimise the available space.


Avoiding thermal management problems


While listing the controllers, modules, and devices, take note of the manufacturer’s recommended minimum spacing distances, if quoted. A key reason for this is thermal management since heat dissipation becomes key within a tightly packed cabinet. Some units may generate more heat than others; even highly efficient power supplies, for example, might yield a few watts of heat. Several items producing small amounts of heat may create a hot spot, potentially impacting other equipment items. Some control cabinets may require forced air cooling, further impacting space. Selecting control units specifically designed to minimise waste heat radiated and suitable for dense side-by-side mounting optimises space utilisation.


Cable management: avoid cable confusion


Cable accessibility, identification and routing are critical over a production asset’s life cycle. Clear identification and convenient


Components in Electronics


fixing methods will ensure rapid, efficient maintenance. Also, depending on cable diameter and type, minimum bending radiuses must be carefully considered - particularly important for optical cables. Routing low-voltage unshielded signal cables from an analogue sensor alongside high- power cables and motor drives, for example, may result in high-voltage transients becoming induced on the sensor inputs, causing erratic system behaviour. The recent rise in popularity of push-in cable terminations helps speed up cabling installation. Spring-loaded connectors provide a convenient, tool-free and reliable connection for solid conductors or pre-assembled cables with ferrules. Insertion forces are minimised, reducing cable stress, while maximising retention and pull-out avoidance.


Standards compliance: electrical and functional safety


Internationally recognised standards stipulate safe separation distances for high-voltage terminals, maximum leakage currents, and minimum electrical isolation voltages. For electrical circuits used in potential proximity to explosive or flammable substances, intrinsic protection regulations apply. These safety standards apply to a system as a whole, including software. Semiconductor devices used in industrial automation systems increasingly feature functional safety features. Examples of electromechanical protection devices include force guided relays.


Electromagnetic conformance and immunity (EMC/EMI)


The industrial domain is electrically noisy. High-frequency inverters, fast-switching motor drives, and high-power motors create an environment that dictates using equipment that meets relevant EMC & EMI standards. Standards such as IEC61000 and the EMC Directive 2014/30/ EU also recommend minimum separation distances between network cables and power conductors. System architects and cabinet designers are advised to check the manufacturer product information and datasheets for compliance.


The future of industrial control cabinet and panel design With many layout and design considerations, the panel builder’s task is daunting. However, control cabinet suppliers now provide a comprehensive set of 3D planning tools, configurators and digital systems. 3D design resources, including 3D models of the many devices and systems placed in the cabinet, allow systems architects to visualise layout alternatives before selecting the optimum arrangement. Once a configuration is selected, the design application can model the thermal profile and electrical dimensioning. Architects can compile necessary documentation and standards compliance certifications with ease too.


www.distrelec.com www.cieonline.co.uk


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