Increasing efficiency and cost optimisation in electrical cabinet construction

More than 60 years of experience make Weidmüller a provider with field-tested knowledge of application requirements, and one that offers an optimised range of products and service solutions for the construction of electrical cabinets. The work process of 'electrical cabinet construction' can be divided into seven phases. The first three phases in the process, consist of designing the electrical cabinet, as well as ordering and storing suitable components. Assembly can begin once planning is complete and the material is available, under phase four, five and six.  The electrical cabinet components are then marked, wired and tested. Subsequently the finished, fully installed electrical cabinet can be commissioned.

To ensure that increased efficiencies are achieved in the long term the individual phases and their process chain have to be subjected to continual examination to uncover their potential for optimisation. Weidmüller offers beneficial solutions for all process steps in the construction of electrical cabinets and in so doing supports the user from the design phase through to production.

Software aided design of electrical cabinets

Planning and designing an electrical cabinet form the basis for all of the steps that follow in the process chain. The aim is to create a systematic foundation, upon which it is possible to continue to build efficiently. With this in mind Weidmüller offers electrical cabinet design engineers the configuration and ordering RailDesigner® software; this makes it extremely simple to make precise selections, plan projects in 2 and 3D and order assembled mounting rails.

"Our customers are able to conveniently plan their projects on the basis of product data provided by us using their familiar CAE software, for example EPLAN Electric P8, ZUKEN E³.series or AUCOTEC ELCAD and Engineering Base. All interfaces are made available to this end. Following a direct data export the RailDesigner® then carries out the remaining configuration", explains Klaus-Peter Hornetz, head of eBusiness at Weidmüller.

More advantages of the RailDesigner® software

• Fast and effortless transfer of the data from the CAE system thanks to the integrated interface
• A full set of manufacturing documentation including visual support that serves as a basis for the simple and time-saving installation of components in the electrical cabinet
• Embedding of 3D data from RailDesigner® into a CAD system to facilitate an advanced simulation of the electrical cabinet construction in order to make early checks to see if compatible components were envisaged during the planning phase

Individual and watertight product selection

As well as the planning and project engineering RailDesigner® software, Weidmüller's online product wizards offer an individual and watertight selection of products, required for an electrical cabinet project. Numerous functions support the user in selecting suitable components from Weidmüller's assortment of products. Wizards are available for products such as surge protection modules, heavy-duty connectors and Industrial Ethernet cables; these lead the user to a suitable selection in line with his requirements in a matter of just three steps:

• In the first step the user enters the desired technical specifications, such as inserts or contacts. In response the product wizard suggests a list of components that match the customer's search criteria.
• In the second step it is possible to further define the product selection or view technical data in the online catalogue, which can be launched with a single click.
• Finally, in the third step suitable components are selected. The product wizard automatically suggests appropriate accessories in a selection window. An order request can now be generated for the products and corresponding accessories that have been placed in the basket.

Reducing the number of variants for efficient logistics and procurement management

To make procurement and storage of the ordered products easier Weidmüller works continuously to reduce the number of product variants by way of standardisation. One example of this is the P-series PUSH IN terminals, which are based on a resolute variant reduction according to the "3-pitch-principle". Previously, users required a total of five terminal blocks for wiring tasks up to 16 mm². With Weidmüller's PUSH IN terminals such wiring tasks can now be mastered with just three terminal blocks – PDU 2.5/4, PDU 6/10 and the PDU 16.

Another current example is the new family of WMF (Weidmüller Multi Functional) terminals for applications in the field of process control engineering. These combine the functionality of feed-through, fuse and disconnect terminals in a single module. This trend towards a reduction in variants stands for an efficient logistics and procurement management with the associated reduction in costs.

Smooth processes during installation

Once the planning for the electrical cabinet has been completed and suitable components selected the most time-saving opportunity exists in simply sending the RailDesigner® project to Weidmüller via the software. The assembled mounting rails are then delivered – mounted, wired and tested – together with all of the additional services required for the respective project.

It is also possible, however, for the customer to assemble his own components and save time by taking advantage of Weidmüller's process support services. Simple mounting process are facilitated by detailed layout planning using the RailDesigner® as well as a clever product design with good handling qualities.

Only a few clicks away from a suitable marking

The interface from RailDesigner® to M-Print® PRO, Weidmüller's software for marking and ordering labels and markers, supports smooth marking operations. Just one click is sufficient, and RailDesigner® automatically transfers the marking data to the M-Print® PRO. This solution makes time-consuming manual data entry and the resulting possibility for errors a thing of the past. M-Print® PRO users are able to design, print and order their marking material effortlessly and efficiently. They are able to make full use of texts, borders, lines, graphics, barcodes, serial numbers and photos.

With this software it is possible to integrate Weidmüller's ink-jet printer PrintJet PRO in the electrical cabinet construction process. The device is designed for extended use; in conjunction with the integrated loader it can be utilised in multiple shift operations. The ink-jet printing technology employed by the PrintJet PRO facilitates crystal clear printing quality, the highest-possible wipe and scratch resistance as well as, what is to date, a exceptional colour print.

Fast and safe wiring

The wiring follows once the electrical cabinet components have been installed and marked. This is where Weidmüller tools contribute towards increasing productivity. For example, their technologies allow several steps to be carried out in a single operation. For instance the sheath-stripping tool IE-CST can remove the sheath from a cable in two stages in a single operation, whilst at the same time achieving high-levels of repeat accuracy of the sheath stripping result. Furthermore, the thought through ergonomic design of the tools facilitates fast and precise working. The new generation of the stripping tool stripax® has a removable handle shell to ensure that even smaller hands are able to grip the tool comfortably and work with ease.

The connection technology PUSH IN is a further contribution that Weidmüller offers to increase wiring efficiency. More and more components are being equipped with this technology, which stands for intuitive and fast connections, high levels of safety and versatile application possibilities. "The prepared conductor is simply inserted into the terminal point, and a reliable, vibration-proof and gas-tight connection is guaranteed," explains Oliver Seiger, head of business unit Electrical Connectivity. "Compared with connection technologies that utilise a screw or tension clamp PUSH IN enables the user to save up to 80 percent wiring time."

Intuitive and error-proof testing

In addition to mounting, marking and wiring the components the testing of isolation and wiring is another fundamental operation that is required when installing electrical cabinets. Final testing often proves awkward and time consuming, because widely different product variants and designs require a multitude of test plugs, adapters and measuring accessories. With products such as the self-attaching test probe PS ZQV Weidmüller contributes to a simplification of the test process. The test probe is compatible with all cross-connection channels in Weidmüller terminal blocks and, in addition, can be utilised for relays and optocouplers as well as Industrial Ethernet components from the Plug, Wave and Micro series of products. Moreover, the test leads provided enable the test probe to be connected to all standard measuring instruments.

With a combination of terminal blocks and plug-in connectors it is possible to loop in computers via test adapters with which it is possible to test the wiring, locate wiring errors and even identify incorrectly mounted components. With such a test computer it is possible to subsequently document all test and commissioning results for the customer. By utilising test methods like these the fully fitted electrical cabinet can be safely put into operation.