smart wiring for electrical panel design engineering

Smart Wiring for Electrical Panel Design Engineering

& MaintenanceHermann Wagner

Application EngineerEPLAN Software & Service

The Process Chain in Panel Building

Engineering Production Operation

at the installation siteProvides the planning documents, circuit diagrams, mounting drawings, ...

Complete production and assembly + internal electrical testing and delivery to the end customer

Control Cabinet Planning / Production

Total process machine builder with integrated control cabinet manufacturing

From the 1st pageof the circuit diagram

Until operation at the end customer

Electrical engineering Operation

Not considered

The process steps in the panel building are essentially always the same.

The individual design of the process steps is usually different from company to company.


Engineering

Production

Operation

Total process machine builder with integrated control cabinet manufacturingCustomer / Engineering Production

Projecting Phase

Circuit Diagram Creation

Circuit diagram

BOM

Wiring list

Mounting layout (schematic)

Technical specifications

Circuit Diagram

These activities are prerequisites to start the production.

These are usually electrical-schematic that provide only the functional logic.

In general, there is a lack of exact specifications for a correct wiring or automated production.

Production ‘Control Cabinet’

Commission

Mechanical Installation

Electrical installation

Testing

Control Cabinet

These activities include the complete production, assembly and in-house testing of the Control Cabinet Application.

Based on the documents and data provided by Customer / Engineering.


Specification

Clarification of

functional

requirements

Electrical-Engineering

Conditions

Clarification of

installation

conditions

Delivery

specifications

Hardware Design

Functions

Technical

design

Schematic Design

CheckSchematic

Generate Documents

Working in CAE Last corrections

Review and

approve data

Generate

manufacturing

documentation


Error checking

Setting parameters

Test reports

In-house function

test

Cabinet Planning

Commis-sioning

Mechanical Processing

Check data

from customer/

engineering

and integrated

into the system

and processes

Mechanical

NC data

Electrical

Routing

Pre Assembling

Installation Wiring Test

Order components

Commission per

order

Milling

Drilling

Lasering

Cutouts

Deburring

SV components

Cable brackets

PE rails

Cable channels

DIN rails

Terminal Block

(Assembling)

Assembling

Equipment

installed

inverter

SPS

Components on

DIN rails

PE

Grounding

Wire cross-

sections

Control wire

cross-sections

31 2 4 5 6 7

Production

In about 90% of all cases the poor quality of the circuit diagrams prevent the use as a basis for virtual panel building and automatic wire routing & fabrication.

EPLAN Smart Wiring

The virtual planning of the control cabinet is a prerequisite

for the delivery of standardized manufacturing documents and data.


Framework:

• Case study of potentials in the process chain

Number of control cabinet fields (TS8) in 2014: 530

Number AE-Cabinets in 2014: 400

Total number: 930

Number of connections per TS8-cabinet field on average: 500

Number of terminals per TS8-cabinet field on average: 133

Found: 2 AE cabinets include as many connections as 1 TS8 cabinet

Number TS8 enclosure fields on average: 730

Number of employees in manufacturing: 15


• Case study (Process-time distribution)

4%2%4%

4%

6%

5%

43%

22%

10%

Manufacturing Times

Mounting Layout /mechanical

Cut to size DIN rails and wire-ducts

Installation DIN rails and wire-ducts

Marking

Terminal Stripes

Installation on Monunting Plate and Door

Wiring

Testing

Logistic / Material-disposition


• Case study (Process-time distribution and potentials)

0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0

Cut to size DIN rails and wire-ducts

Marking

Installation on mountig plate and door

Testing

Potentials

Optimized Today

To raise the potential in each area, the appropriate conditions must be created in the engineering

Potentials in the Process Chain

• Use of wiring lists

• Prefabrication of wires

• Introduction of systems for visual assistance with wiring

• Inserting pre-assembled terminal strips or

• Using prefabricated terminal strips from the manufacturer

• Direct transfer of drilling information for NC processing machines

• Direct transfer of the necessary information for cutting-machines.Sorting, labelling and cutting optimization of wire ducts and DIN rails included

• Potentials in manufacturing

Potentials in the Process Chain

The time savings comes through:

• Accounts further inquiries to the engineering

• The circuits documentation must not be browsed [exclusively tabular work]

• Always the same form of the circuits [List form]

• Sorting by section, color, length, etc.

• Parallelization of operations [assembling, labeling, wiring]

• Significantly shorter familiarization time

• Optimized capacity utilization control and scalability of resources

• Potential through the use of wiring lists

EPLAN Smart Wiring

With support from EPLAN solutions digital data e.g. for wiring

can be deployed, including step by step instructions for manufacturing.

EPLAN Smart Wiring

The software-based support for the manual activities in manufacturing

allows better scalability of capacity and resources.

• Seamless workflow

• Automated generation of manufacturing data

• Wiring without circuit diagrams

• Step-by-step instructions for the worker

• Project comparison for last minute changes

• Capturing the wiring status

EPLAN Smart Wiring

• Software based support for the panel shop

EPLAN Smart Wiring

Internet browser based software for customers and prospects in mechanical engineering and panel building

Optimizing processes in manual wiring and increasing the efficiency in the control cabinet production overall

The focus is on the production of cabinets and not on engineering and production planning

Providing complex wiring information in a clear and understandable way for the worker in production

Time-consuming search and interpretation based on the circuit diagram is omitted. The detailed knowledge is provided by the software.

EPLAN Smart Wiring is designed to support less well-trained staff in the manual wiring of control cabinets

EPLAN Smart Wiring

EPLAN EPDZ-File

MS Excel FileE-CAD

• Workflow

Software Presentation

EPLAN Contact Information

Hermann WagnerApplication Engineer

EPLAN Software & Service425 N Martingale Road

Suite 470

Schaumburg, IL 60173

USA

(847) 240-4667

[email protected]

www.eplanusa.com