Issue eplanet special

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1 E D I T O R I A L Issue eplanet special Dear Readers, In spite of the economic predictions and the current financial crisis, the international market still has exceeded growth expectations. We are not only seeing positive figures in all important economic indexes and business climate key data in 2011, but the order books have been continuously filled and companies are set up for long term growth. Now industries current challenges consist of scarcity of resources with a lack of technical experts and the upswing in orders with a time consuming engineering process. EPLAN has the perfect answer; through EPLAN s portfolio of E-CAD and CAE tools and services we are able to deliver effective process optimization strategies to take the pressure off of product development and its tight deadlines. Variant management and modular kit based configurations turn out to have powerful potential for optimization. EPLAN Engineering Center together with our integrated product platform is able to make the complexity of product development manageable and makes clear that standardization and flexibility are no contradiction, even in the customized mechanical engineering field. Beginning this fall and coming spring we will be presenting evidence with clear best-practice solutions live, at more than 40 international trade fairs. We are looking forward to your visit. Maximilian Brandl President of the Management Board Stay Focused Essential impact of strategic engineering Staying vigilant. Flexible responses. Decisive takeoff. This is just as valid in daily business operations as it is in sports. The present economic situation demands a correct strategic assessment and complete concentration and focus on the essential. This most recent spike in orders does reflect enormous challenges, as a recent order study by the VDMA* attests to. The V-shaped recovery after the recession slump may even indicate an overcompensation of the most successful years. What this means: Whoever learned to manage the tight deadlines, handle maxed out capacities, scarcity of experts and resources with unfaltering flexibility will be able to reach the target quicker. Success is predominantly a question of strategy Strategies focus on creating successes and only the ones facing these challenges head-on will be successful. It is paramount to extract the right lessons from this crisis and the various companies in our study display quite different approaches to their solutions. Only 15% of the mechanical and electrical engineering firms admit to a defensive strategy. Their focus is on decreasing risk and speed of growth with special focus on early warning systems and risk management. Via our survey, 32% of the companies apply a buffer strategy, increasing flexibility for capacities utilization, fixed costs and working time. 42% of the companies display a winning attitude The majority of mechanical engineering firms (42%) are taking the growth in stride. They concentrate on process improvements, the application of new technology and depend on measures that facilitate the power of innovation and productivity sustainably. This means, developing their employees toward specific goals and improving their own skill sets. The foundation: comprehensive measure to consolidate the company s know-how, expand it and to retain employees for long commitment periods. Measures that match up organization working methods and software to the optimum level. Taking the action reins into your own hands Numerous EPLAN customers have used the past two years to prepare for this anticipated recovery. Engineering processes have been optimized, established procedures have been critically examined and measures have been implemented with consistency. The potential for sustainable optimization is right there, in the synchronization of all individual project phases and interdisciplinary workflows. Example: Certain preparatory work on the engineering level, quick commissioning, made possible with machine and plant documentation, standardization and process analysis, all make production more flexible. The process from order entry to revenue This consistent strategy of offense has proven itself with first successes already. EPLAN demonstrated Best-Practice examples at the Hanover Trade Fair 2011 by showing how your incoming orders pay off in productivity and revenues gained. One possible solution approach is consolidating all product know-how. Instead of designing machines/ plants with numerous variations manually, the transparent rules make configuration much easier. Integrated project documentation can be generated with just the touch of a button. This facilitates growth and expansions in highly dynamic markets. *Commissioned study of the IMPULS foundation of the VDMA: Lessons from a crisis, December 2010 Heller: Mechatronic design EPLAN Pro Panel: Engineering XL Great achievements: 50 years of Rittal Speeds up: IT & ERP integration 3 8/

2 All inclusive package From CAE to ERP and vice versa: SAP interface accelerates design process Quick&customized. When Pester Pac automation GmbH develops and produces a highly automated packaging plant, this will usually be a unique design. Why? Because the product determines the machine. The company faces its reality of very low repetition rates in design, short development time and the ongoing demand for efficiency with integrated data management between CAE and ERP. Pester was able to realize automatic work processes in their electrical design by migrating to SAP and the Eplan Platform. Their secret to success: standardized modules from basic machines Pester, an internationally known manufacturer of packaging systems in the pharmacological and cosmetic industries, has the entire process chain under control: from foil packs, to carton packaging, all the way to palletizing. All their machines are designed customer specific, since form and quantity of the products for each application will most likely be different. Helmut Weber, Manager of electrical engineering: We therefore use standardized concepts from basic machines for efficient design processes and utilize our library of functional subassemblies. Coupling ERP does save time and minimizes errors Pester started with a decision for an interface between EPLAN and the ERP system used at the time, since the design time factor appeared to be taking on more and more importance. Automatic data transfer of electrical engineering data to procurement and production planning did not only save time, but it also minimized the rate of potential errors to nearly zero within a short period of time. That convinced the company that they would want to apply the advantages of a CAE and ERP connection even after the SAP implementation. Integration link requirements were coded in with ILC Prostep, Eplan s SAP integration partner, right from the beginning. The standardized SAP interface called 4PEP Connect Eplan was introduced at the time of the SAP implementation. Pester s objective was to maximize integration of the two disciplines already during the preparatory stages. For instance, the interface sets up identical part numbers in both systems and the bill of materials will be automatically transferred into the SAP system via the interface. Inconsistencies as a result of double data in management systems: a thing of the past. In fact, avoiding redundant data management was the primary objective in the coordination and design of the interface. We have succeeded and the positive effect is definitely noticeable. Helmut Weber: The processes in electrical engineering and procurement are now easier and much more concise. Eplan, together with ILC Prostep adapted the interface to Pester s requirements to be able to achieve the maximum degree of automation and to exploit any possible rationalization potential. Separate lists are generated for each: enclosure manufacturing, pre-assembly and the final assembly. Permanent synchronization of bills of materials and order lists In addition, the output will be chronologically structured: Let s consider a complex enclosure, which is considered a longrunning part. A preliminary bill of materials will be issued that allots enough advance time for production. Ordering of special motors and other purchased parts with long lead-times may also be initiated way ahead of time via this function. Deep integration of Eplan Electric P8 and SAP does have the distinct advantage of ongoing synchronization of bills of materials and order parts lists in SAP during the entire ordering and assembly process. Both systems work with an always identical bill of materials, each of which considers current order entries or in-house production parts. This basic functionality of the interface was optimized for Pester as well. Helmut Weber tell us: Omissions and The processes in electrical engineering and procurement are now easier and much more exact. Helmut Weber, Managing director electrical engineering for Pester Pac automation GmbH errors have been eradicated almost completely with the transfer of the bills of materials, because the interface has already performed an automatic plausibility check at this point. For example, it checks if the parts listed are still valid and are still released for ordering. If that should not be the case, the system reports the part in question and the designer can immediately recommend a replacement part. That guarantees quick and error free processes. 2

3 Plan with a click Mechatronic design standardization with flexibility This is how process optimization works today: Sales representatives choose customer selected options in a configurator. The EPLAN Engineering Center (EEC) automatically combines all selected modules the schematic is generated almost without any manual effort at all. A good example for perfect integration of all disciplines into one integrated design process is the engineering at Heller, a machine tool manufacturer. One look at the prior design efforts explains why Heller reduced its time and cost primarily with the integration of electrical and fluid engineering processes. Their production lines of up to 40 machines and numerous man hours, this is a large cost factor. Automated processes, mechatronic design Heller develops and manufactures 4 and 5 axis machining centers as well as flexible manufacturing systems for the automotive industry all over the world. A few years back, the creativity of the company s approach to process optimization was completely driven by the complex project planning, such as Heller machines for motor block and cylinder head machining processes. Klaus Riexinger, Senior Manager Controls Engineering: Our essential goals were a common platform for electrical and fluid engineering and a system that could actualize the prerequisites for truly mechatronic design. Fluid power engineering was not to be Deep integration with the Eplan Platform From then on Heller designed with this new design method, such as their 5 axis machining centers series F and the results were completely convincing. The next level of realization was accomplished at Heller with the introduction of the Eplan Platform. Michael Gneiting, system administrator and electrical engineering designer, considers the introduction of EPLAN Electric P8, EPLAN Fluid and EPLAN Cabinet as an absolutely positive move: The individual trades are working with the same model, and also use the same designations, thanks to an object oriented approach. This greatly simplifies the processes and avoids The designers should not need to invest their time in tasks that can be automated. They should be able to apply their creativity that is our bread and butter. a mere appendage anymore, because hydraulics, pneumatics, lubrication, cooling lubricants and machine cooling combined make this trade quite complex. The Eplan systems for electrical and fluid power engineering and panel layout together with the EPLAN Engineering Center (EEC) are able to offer the desired comprehensive solution. Klaus Riexinger, Senior Manager Controls Engineering, Heller inconsistencies, which were a recurring problem in the past. Sales configurator for customer consultations At Heller, automation starts at the sales level: The consultant works with a Sales configurator, which assists in configuring the machine from more than 100 options. It really is quite simple; for example, he enters the size of the tool magazine or selects add-on functions like drill bit breakage check and measuring probes. The introduction to modular based engineering is easy, since an electronic design module is located behind each click, which then is automatically called up in the EEC. Same task same solution identical design This workflow automates the electrical design for standard machines enormously, always retaining the option of manual modifications of course. Technical information is stored in macros, which are then linked with Parts management. In case of customer-specific additions, design engineers access the same data and macros in Eplan Electric P8 via the Parts master data navigator. Klaus Riexinger: This method ensures that identical tasks are resolved in identical ways and using identical means. The prints are the same as well. Enclosure design with EPLAN Cabinet benefits as well: Routing is generated just as automatically as the printout of device designations. And there is another advantage, Mr. Riexinger tells us, it has changed the procedures of employees working with wiring lists. NC machining of the enclosures is also done per CAM from within EPLAN Cabinet. Quicker design processes, all the way to production In other words: Designing with EPLAN Platform relieves Heller s designers of repetitive tasks and lengthy searches for parts at a total of 21 Eplan workstations. Klaus Riexinger: Design engineers should not have to invest their time in tasks that can be automated. They should apply their creativity it is our bread and butter. Integration and standardization not only creates more flexibility in the processes of fluid power and electrical design engineering, but it also steps up the pace in production especially in the manufacture of electrical enclosures. 3

4 Engineering actively accelerated The new Eplan Platform 2.1 has arrived Standardization and automation are the main focus of Eplan Platform 2.1, which has just recently been released. Automatic macro updates, targeted use of test routines these and further functions bring about rapid results and increased quality. Even larger projects can be managed easier with the Eplan Multiuser Management module. EPLAN Platform 2.1 Standardization simplifies engineering processes, but what is the easiest way to implement it? Macros now are considered a must and they can be updated with just the push of a button. Eplan Platform 2.1 keeps users flexible in the process: The new Update macros function makes sure that all data is updated to the most current state, either individually or automatically. Partial circuits that have already been inserted can be updated effortlessly. Macro master data changes can easily be adopted into currently active specific projects. These high-grade templates guarantee consistent quality in the project and a standardized engineering process. Multiuser Management Large automation projects will often be worked on by a number of quite diverse project participants. How can one keep that amount of data transparent and compact? The new module Eplan Multiuser Management provides the solution. It is able to divide projects into separate process areas, which can then be structured using identifier blocks. The division is done based on the structure identifiers already existing in the project. Setting up process areas can be designated to the user or it can be centralized with the administrator. This method simplifies the concentration on any particular area of responsibility. At the same time, Eplan Platform 2.1 ensures that all project information is globally synchronized. Helpful navigation functionalities are available as well. A clearer overview is created, system reaction time for the user speeds up and it consequently leads to increased quality in project planning. Creating variants with Rotating and Mirroring A new functionality has been developed especially for fluid power engineering; it gives a distinctive performance surge to project planning, as well as High-grade templates guarantee consistent quality in the project and a standardized engineering process. master data creation. Rotating and mirroring contains its own logic and speeds up; i.e., creation of schematics or fluid plans up to factor 2. Only one half of the plan is left to be designed by the user - the second half can be generated with the intelligent mirroring technique. In the case of symbols, the acceleration can be as high as factor 8 because the eight angle variants of a symbol or a macro no longer need to be done manually. Creating one single variant suffices and all other representations are delivered by the system with the respective automatic rotations and mirroring. Automatic correction checks Manual project checks can take up considerable time, therefore it is a real plus for the system to take over this work. The check type Prevent errors was already introduced with version 2.0; it actively prevents the user from entering incorrect data. The new version continues to pursue this path. The user can now apply check routines specifically to newly entered corrections during a project review. The Eplan check routines are then concentrated specifically on newly edited project sections, which leads to an even higher quality standard in machine and plant documentation. This focus facilitates specific testing of corrections and can create a sustained increase in project quality. 4

5 Maximizing potential Brilliant working experience with the highlights of the Eplan Platform It does not come as a surprise to us that during the current surge of orders, the abundance of facets in EPLAN Platform have hardly been explored and discovered. Version 2.0 has been on the market for a year now and many of its highlights and more than 1,000 new functions have not even been utilized yet. That is reason enough to take a closer look at version 2.0 from a new perspective and discover new content. Revision control: clear & precise Who has not experienced this issue? Right before the project is ready to be signed off a number of changes arrive, which have to be entered carefully and which must also be traceable according to norm requirements. This is where the strengths of EPLAN revision management can come into play; the program not only ensures security, but also speeds up revision control considerably. The new options guarantee a better overview, by using different colors and symbol shapes to identify different types of changes. All project members can tell at a glance if project information has been added, changed or deleted. A table summarizing all changes makes sure that all processes run smoothly in engineering and especially in manufacturing, commissioning and maintenance. The keyword is As-built documentation. The direct result: faster start-up phases and shorter machine downtimes. Stand-Alone version: EPLAN Central Parts Management A cost-effective alternative: Those who store and update part data centrally, separate from the engineering department, can now use Eplan parts management even without an Eplan license. The CPM module, short for Central Parts Management, is a stand-alone version that provides a simple alternative for the company s business departments. Data and item information created and stored here is now directly available to all Eplan users. This will simplify cost-efficient maintenance with full functionality of the parts management. The Central Parts Management module is a simple alternative for a company s business departments. Previously created data and stored item information is now directly available to all EPLAN users. Property management with a value and unit of measure The logic support makes the difference in a CAE system and it is in every respect convincing in version 2.0 or higher. Detailed specifications for displaying and converting stored values and complete technical SI units can be defined for item properties. For instance, the display of electrical power of drives (electrical motors) in the schematic in kw regardless of a power entry at the part in watts or even the lack of an entry altogether. The same holds for reports where the displayed performance values can be standardized. Even for calculations used in forms, it can be ensured that values are fed into a calculation with the same units of measure, regardless of how they were entered in the schematic and that the results are correct. Professional and for real life conditions: Language management It is not news that Eplan is Unicode compatible and designed for 16 international languages. What is new is the setting allowing the user to differentiate between the source and one or more display languages in a project. The source language is the language in which the text was entered, usually the native language. The display language is the language in which the text is displayed in the schematic this can be in many languages, at the same time. Entering text and dealing with translations is even more transparent and it is much easier to work with foreign languages in the design. This is a real advantage in terms of time and quality, especially in the daily global business environment. Eplan Platform Overview of more trips and tricks 1 Redlining: With Acrobat Reader X Insert revision comments and transfer into Eplan for processing. 2 Potential tracking: New device connection types for logical potential transmission also inside of black boxes. 3 Standard compliant function identifiers: Comprehensive characterization of terminals as default in parts management, or application specific in the schematic. 4 Filter scheme in the page navigator: Simplified, reusable filters create clarity even in larger projects. 5 Multifunctional PLC terminals: Defining properties contingent upon their specific use in the project creates distinctive flexibility and reduces the amount of master data. 5

6 Empowering energy solutions EPLAN Platform: Optimizing Design Productivity Russia relies a great deal on localized heat and power generation. For Impuls Industrial Boiler Plants, the opportunities for building or rebuilding large boiler houses that provide heat and often power to communities and remote industrial installations represents a major growth market. Founded in 2002, the company has pioneered development of modular, fully automated industrial boiler houses that don t require a human operator. Needed state of the art design tool Design plays a crucial role at Impuls; over half the staff of 100 are engineers. The company recognized that its old software tools were too constraining. Engineers were using AutoCAD to design power equipment, automated heating systems and instrument and control (I&C) systems and MS Excel to draw up bills of materials and other lists and tables. Engineers had to connect assemblies and control devices manually. There was no way for the different engineering disciplines to share content or work collaboratively and no way to archive commonly used content. With so much manual processing, it wasn t unusual for major errors to creep into projects that were a challenge to fix, especially when projects were on deadline. says Alexey Soloviev, head of the engineering department at Impuls Attracted by EPLAN Platform concept Seeking to optimize design productivity, Impuls selected EPLAN for its vast automation features and because its database-driven suite of products was unique the only computer aided engineering product that supported electrical, process control and enclosure design on a shared platform. That meant data generated by one discipline could be shared by all, says Soloviev. Switch generated major time-savings This was a capability the company wanted. Before we decided to use EPLAN for our engineering, working in AutoCAD and MS Office meant all product stages were executed by one and the same engineer, because functions like cross-discipline designing and multiple users sharing data were lacking. Now, With so much manual processing, it wasn t unusual for major errors to creep into projects that were a challenge to fix, especially when projects were on deadline. with EPLAN, the electrical and process control engineers have the chance to collaborate together on projects. Alexey Soloviev, head of the engineering department at Impuls With the switch to the EPLAN Platform Impuls acquired EPLAN Electric P8, EPLAN PPE and the 3D mounting panel layout module projects that typically took three months or more are being completed in 5-6 weeks, and that was achieved within six months of switching to EPLAN. Engineers are making maximum use of EPLAN s vast automation functionality, like automated errorchecking and cross-referencing. Error rates are down, and it s not unusual to have projects that are completely error-free, says Soloviev. An archive was created in EPLAN and now contains over 1,500 component macros and 2,000 function macros shared by all disciplines. Impuls expects that over time, it can accelerate projects further by increasing the number of archived macros and recognizing more ways to take advantage of EPLAN functionality during project development. Customers like EPLAN results With EPLAN, he says there should be a maintenance benefit over time for both Impuls and customers since the documentation generated by EPLAN for each installation is a higher quality. We have noticed that our customers have far fewer questions with regard to (completed) projects and tend to grade the ones done in EPLAN very well. 6

7 Global player global standard Benefiting from universal, standardized design In the automobile industry, markets are national, such as China, but as South Korea s Hyundai Motor Company manufactures more vehicles abroad, it has seen the need for a transnational approach to engineering. Using different legacy CAD tools to get overseas car and truck plants up and running had its share of adverse consequences. Now, Hyundai has adopted EPLAN Electric P8 with its powerful database as the platform on which to implement a universal, standardized approach to electrical design, including the launching of new model and plants. The objectives include enabling the automaker to adapt more quickly to changing market conditions, making design more efficient and improving collaboration with suppliers, contractors and other business partners. Implementing EPLAN was a priority at Hyundai s third Chinese plant, at Beijing, where it is being used as the primary electrical design tool for setting up the body shop of the brand new facility. The Hyundai Motor Company operates plants in several countries. In accordance with industry practice, when a new model is introduced, production lines are retooled, which involves re-engineering existing systems, components and production equipment. Everything must fit the new model precisely. The same is true of setting up production lines. But Hyundai lacked a database of electrical drawings for installations in the field, which made it quite difficult to replace or modify that equipment. Overseas projects exposed need for design standard When the company established a plant in Alabama in 2004, the lack of accurate drawings caused serious problems, says another engineer. Though the company had been considering standardization, we never achieved it, since we had never experienced particular problems working with domestic partners (in South Korea), even without accurate drawings. However, our partners in the United States used electrical drawings that comply with an international standard, which was different from what we had. This incompatibility caused many difficulties. Furthermore, converting assembly operations for new models was a painstaking process due to the lack of existing drawings, history and design databases. We desperately needed a solid standard. That s why we have implemented the electrical design system with EPLAN. Though the company had been considering standardization, we never achieved it, since we had never experienced particular problems working with domestic partners (in South Korea), even without accurate drawings. Database of authorized parts supports standardization There used to be a chronic problem because of inconsistencies between the design of some pieces of equipment and their performance in the field. Now, engineers must use only registered parts stored in the E-CAE database. Considering the complex and diverse facilities involved in automobile production, it takes strong leverage like that for standardization to be effective. Hyundai Motor Company s plan is to implement EPLAN at all new plants, like Beijing and another set for Brazil, prior to construction. Though the system is currently being applied to body shop (welding) operations only, it will cover power trains as well in about two years. We expect to gain a significant boost in efficiency in the power train field when EPLAN is introduced, as that area has separate divisions for designing and test driving, a Hyundai Motor Company official said. 7

8 Premiere in size XL Available now: EPLAN Pro Panel presented in full configuration level The roll-out: EPLAN Pro Panel makes its debut with the new Professional Version. What started with high-performance 3D mounting layout turned into an integrative XL engineering solution for enclosure layout. Project planning, 3D layout, manufacturing and mounting are merged, through a uniform data basis, to form a fully integrated solution. A considerable increase in added value has been pre-programmed by rendering data conversion and reverse engineering are no longer necessary. Integration from engineering to production Suspense included: EPLAN is able to considerably alleviate some of the pressure of deadlines and cost reduction in enclosure manufacturing, and with the fully equipped version of EPLAN Pro Panel. The roll-out presentation on international exhibition floors will demonstrate: Automation engineering, mechanical engineering and plant engineering all reap the benefits of an interdisciplinary engineering tool that covers all trade-specific requirements. The ability to work parallel and on a uniform data basis accelerates product development as well as the enclosure production. A fully integrated solution for enclosure manufacture, no longer applying data conversion and reverse engineering, creates sustainable cost reductions, quality increases, and reductions in Time to Market. Uniform data automatic and always current The keyword is integration, with Eplan Platform facilitating the exchange stage. Devices that were designed in electrical and fluid engineering can now be used directly for the 3D mounting layout. Data synchronization that almost always used to be necessary between the two systems involved, or the time consuming feedback of bills of materials information, are no longer needed. This sustainably reduces any efforts invested in interdisciplinary data synchronization and the provision of comprehensive bills of materials in industrial automation engineering. Engineering with productivity assurance Product development processes in electrical enclosure engineering gain discernable momentum, while redundant data management is no longer necessary. There are a number of work steps and typical reverse engineering expenditures that can be taken off the to-do lists now. Project synchronization, a known source for errors, dries up immediately. The Working parallel on a uniform data basis increases product development, as well as production in enclosure manufacturing. functionality of EPLAN platform s key basic functions such as revision control, rights management and special programming with API can be fully applied and that s far from everything: Integration moves on in the direction of manufacturing, mounting and wiring. Profits can be created as a result of the transparent process view direct data transfer to NC machines, conductor routing and cable fabrication to ensure the seamless workflow across the entire product creation process. Reliable planning - correct manufacturing Whether dynamic collision check or automatic checking of relevant installation conditions: EPLAN Pro Panel makes professional 3D layout planning easy, even for the occasional user. Production data for drilled holes or milling is easy to work with, as it is integrated into the 3D model right from the beginning. You have the flexibility of creating special drilling templates aside from the associated mounting diagrams. Another decisive practical advantage: In the creation of master data, manufacturing information is stored only once even for length-variable parts such as cable ducts or mounting rails. Then components and NC data can automatically be integrated in the respective mounting layout, a sure way to fast results and consistency in quality. Modifications to housings, doors or mounting panels are simply transferred to the appropriate manufacturing systems for each NC interface the available interfaces to milling machines by Steinhauer and Kiesling are some of the examples of this deep manufacturing integration. Flexible conductor and cable routing More flexibility in routing 3D conductors: Now, cables, as well as conductors, can be routed within a 3D mounting layout. The new found efficiency flows over into other areas as well. Path networks can be defined in a space and connections routed intuitively if so desired, independent of the planned wire ducts. New layout areas further expand the 3D routing possibilities and also support virtual and automatic wiring of Lütze frame systems for example. The software routes wires and cables on the shortest possible route through wiring cut-outs to the rear of mounting panels, dividers or other enclosure components. Once the wiring and cabling of components have been length-optimized, the results are used to perfect the schematic the idea is net 8

9 EPLAN Pro Panel Enclosure layout: The integrated approach all the way through to production based wiring. Connections from the mounting layout s 3D routing can be led back into the schematic, based on the improved pathways and sequences. The now improved schematic sections are marked accordingly and can be edited further by using the optimal EPLAN Netbased Wiring module. The essence of engineering: Data, data, and more data Where would engineering be without the correct device data? EPLAN Pro Panel offers a number of access options, even to the 3D geometric data. This is handled by the integrated STEP interface. No matter if received directly from the component manufacturer, imported from any 3D CAD system, or via diverse data portals and data CDs like RiCAD 3D by Rittal: The 3D data is simply read into Eplan Pro Panel and partially automated, or interactively changed into qualified Eplan Macros for use in the 3D mounting layout. Support of Eplan s Accessory management is completely new in this context. Selectively extended and adjusted to the specific requirements of the user working with the mounting layout accessories can be defined and stored for a particular enclosure series. System-Know-How and permitted combinations are also included. Stored accessory components are compiled for placement in the mounting layout and then finally positioned. Should an accessory component have a placement variant, meaning, a defined position in the enclosure, positioning will be automatic. The newly defined placement concept of Eplan Pro Panel ideally supports the user with all accessory components that do not have a predefined position. All necessary accessory parts will be offered at the cursor, one after the other, and can then be placed interactively at the intended position. Optimized support using innovative etouch technology Eplan Pro Panel Professional creates sustainable cost reduction, increased quality and reduced Time to Market. Migration made easy A promising outlook for the users of Eplan Cabinet: You will be able to continue using Eplan Cabinet data in Eplan Pro Panel. The XL variant of Eplan Pro Panel provides extensive functions for transferring existing data and integrating it in the Eplan Platform. Eplan Pro Panel adopts all significant parts data and associated 3D graphical macros, 3D enclosure templates, or parts from the Eplan Cabinet accessory management in perfect harmony. The latter, of course, includes integration with the accessory management of the Eplan Platform. Not only can you adopt 3D mounting layouts from Eplan Cabinet but you also have the option of integrating with the Eplan Electric P8 projects directly and automatically. Component connections between the schematic and 3D mounting layout are established by the system. Simple Eplan specific navigation within a project is possible in the bidirectional editing in the schematic or 3D mounting layout. The keywords, for example, are jump functions and interdisciplinary part processing. Since Eplan Cabinet accesses the identical Eplan parts database as all the other programs of the Eplan Platform to create and maintain parts data, all existing parts data can be reused for Eplan Pro Panel. All the way to production Finally, Eplan Pro Panel Professional also ensures the adaption of manufacturing based data that has been defined in Eplan Cabinet. Drilling patterns for parts and conductor connection point patterns for devices can continue to be used. It is also possible to import freely defined NC specific outlines for cut-outs and recesses from Eplan Cabinet and reuse them in future designs. In the case of high-value device data for project planning in schematics and 3D mounting layout space, Eplan Pro Panel and its connection to Eplan Data Portal earns points because it is able to integrate components easily into the device list or the 3D mounting layout. Highlight: the connection to specific item configurations like Rittal Therm, which are able to support the configuration and design of entire assemblies and modules, along side the actual parts data. The parts data for configuration solutions is combined in the Data Portal and then transferred into the Eplan device list. The result: a highly efficient device and module integration in the 3D mounting layout. 9

10 Enclosures from the net Eplan Engineering Center as the foundation for a web-based business model There is nothing better than an excellent idea to win new customers. Observe the new business model Easy Panel, created by P&V Elektrotechniek, based in Zolder, Belgium, which is now online at since summer The company is offering simple and cost effective enclosure self-configuration at which is then followed by an almost completely automated production. The backbone of the configuration surface will be the Eplan Engineering Center (EEC). This is an ambitious goal: developing new markets Presenting a wealth of ideas and technical know-how are both traditions for the Flemish. P&V Using the data from EEC the robot can not only plan the routing, it can automatically perform the wiring. Elektrotechniek is probably one of the most important companies in the field of Belgian enclosure manufacturing. Founder and Chairman of the Management Board Ghislain Vanherle: Our clientele, so far, consisted of midsized machine and plant design firms and we usually did repeat orders in various individual variations. Project planning for large scale plant construction had not been our target market up to this point and also not individual custom orders from smaller electrical companies. That is exactly what is changing now. Ghislain Vanherle, Chairman of the Management Board P&V new business model for our new customer group, and we defined two prerequisites for it. First: Webbased configuration of the enclosure by the customer, and completely standardized processes, from inquiry to delivery. Second: almost completely automated production of the enclosures. Step 1: standardized, user friendly processes P&V bravely broke new technological ground and developed an online tool that allows drag & drop configuration of enclosures up to 630 ampere. At least they didn t have to start at ground zero. P&V relied on the EPLAN Engineering Center (EEC) which uses technology that provides all the requirements for standardizing the processes as needed. Alain Beliën, electrical engineer, about the procedure: The customer defines or designs his enclosure online, which results in a configuration file that he can send with the push of a button. EEC configures the enclosure right away, even the automated calculations are done with the data from EEC. The customer receives, again mostly automatic, an offer that the customer s OK will turn into an order in the P&V ERP system. In parallel, the EEC prepares data for the wiring robot and CNC machining of the enclosure. Step 2: enclosure manufacture with robotic support at P&V At the same time P&V was working on making prerequisite number 2 a reality and developed, together with a robot manufacturer, a wiring robot. Ghislain Vanherle: Using data from the EPLAN Engineering Center, like wiring schematics, terminal lists and device lists, the robot can not only plan the routing, it can perform the wiring automatically. The robot independently carries out all production-relevant steps. Starting with the selection of the right tool for conductor end treatment, the robot labels all conductors and even automatically connects the conductors to the right components. Economic production can now be achieved with small lot sizes. That means integrated automation, which allows the efficient production of smaller enclosures even in a lot size as small as 1 with quality standards as you would expect in mass production. Moreover, the EEC communicates independently with the other IT platforms: with the Easy Panel user interface, the ERP, the CNC controlled production systems, as well as the wiring robot. This integrated flow of information frees up incredible rationalization potential. Starting with configuration, ending with production P&V and Easy Panel will be addressing numerous smaller companies and distributors, which are in need of only smaller quantities. Ghislain Vanherle: We realized that we would need a completely Wiring robot: Rollout at the Hanover Fair The startup of Easy Panel is imminent. Ghislain Vanherle: The robot has been introduced at the Hanover Fair this year, now we are online with our solution at 10

11 Data Express Better integration: New Eplan interface to the PDM system Vault Knowing what others are doing. Anytime, anywhere. This is how teamwork is supposed to work this is how the data express starts rolling. In short: Nowadays efficient product development cannot exist on the optimized expertise and automation of just the individual engineering tools anymore. Machine and plant designers have long recognized that one gear wheel must be coordinated perfectly with the next one so that everything can run smoothly and concurrently. Therefore the key to success is the integration of individual design disciplines into one comprehensive PLM concept. Simpler is faster The trend towards mechatronic demands absolute transparency, throughout data management as well across all disciplines. This bridging between electrical, fluid and mechanical engineering is accomplished by the new Eplan interface to the PDM System Vault. The result: A mechatronic workflow, which simplifies and accelerates the entire engineering process. Workflow meets data management Rather together than alone: Design data from AutoCAD Inventor or Mechanical is now managed together with electrical and fluid engineering projects, using the bidirectional Eplan interface to the Autodesk PDM System Vault. A clear advantage: one workflow one set of data management. The direct connection between the PDM System and Eplan Platform 2.0 makes the highest degree of transparency possible. Further practical advantage: The process becomes mechatronic. The integrated revision management approach speeds up data organization in mechanical engineering and CAE, ensures a dependable release and tracking procedure of project data, and reduces errors in the design process. All data may be accessed immediately throughout all departments and is centrally protected against unauthorized use. Simply check in projects The Vault server manages the M- CAD design data as well as all project data from Eplan Electric P8, Eplan Fluid or Eplan PPE in one centralized structure. All information will be structured across disciplines - the multitude of variants within the company is finally under control. Furthermore, established standards will ensure a consistently high quality and expedited design processes. About the procedure: Complete CAE projects may simply be checked into the vault and saved. Characteristics lists and structured bills of materials are a must in helping with the systematic allocation of components and component groups into superordinate classes, thus rendering the perfect overview. Central parts management A win for clarity: The new Eplan interface for Vault simplifies Parts management as well. All set up parts appear in the PDM system. This facilitates complete and comprehensive bills of materials that contain valuable information such as part numbers, supplier or manufacturer. An additional engineering advantage is that structured bills of materials with higher-level function/mounting location structure may be The new EPLAN interface with the PDM system Vault facilitates simultaneous management of mechanical engineering data and industrial automation engineering. transferred as well. Information about bills of materials is available bidirectional and across departments for perfect parts data synchronization. Even the header data for CAE projects can now be managed easily via the Vault. These can be configured freely and are identical in both systems. This completely ensures the Eplan user that characteristic project data will always be current. Creating PDF automatically The PDM system s integrated viewer automatically delivers Eplan projects in PDF format and in addition offers extensive navigation possibilities. Cross references, component jump and the comfortable page navigation are only a few highlights that will provide quick and easy project overview for the user. By the way, Vault users may view complex CAE projects without their own EPLAN license PDF makes it possible. This way all participants can be up to date about the current project status at all times. The individual synchronization efforts can be reduced, which will save time and lower project costs. In other words Eplan/Vault integration forces an efficient product development process from design to production. At the same time, horizons in the data management field, and the often still separate disciplines of mechanical engineering and CAE, will be broadened with integrative and interdisciplinary engineering insight. 11

12 Creating the future Rittal: The inventor of mass produced standard enclosures is celebrating an anniversary Rittal started with the series production of four simple enclosure types in Today, 50 years later, the inventor of the mass produced electronic enclosure is able to refer to an extraordinary success story. The family owned company with 10,000 employees is one of the international growth champions and was able to establish itself worldwide as a leading systems provider for electronic enclosures, power distribution, system climate control, IT infrastructure, as well as software & services. The 1,500 patents around the world are proof of an exceptional culture of innovation. In this anniversary year, Rittal takes the opportunity look at yesterday, today and forward to new future oriented product developments. The 1960s as the early years of automation Big ideas often start out rather small as was the case with Rittal as well. The 60s were the period of industrial automation. They started the era of industrial electrical engineering with electrical switching, regulating and controlling. A simple hint from the wholesale electrical industry was enough for Rudolph Loh, the founder of Rittal, to set off the initial spark. That hint had to do with sheet metal boxes serving to protect electrical controls, which, until then, had been produced individually and by hand. Of course, this demanded a correspondingly high price and along with it long delivery times and a good many quality risks. This was the beginning of the idea to produce enclosures in fixed standard sizes economically, in mass production, warehouse them and market them professionally with the slogan: The enclosure you will need tomorrow has already been built... TS 8. A single modular kit for precise solutions in main power distribution, industrial automation, building installations, network technology... yesterday, and it is ready for delivery in our warehouse today. Sold by the millions: Rittal PS 4000 baying system In the 70 s, industrial automation really took off. Different requirements for an electronic enclosure, like more flexibility and solution variants became an issue at that time. As time passed, power distribution and system climate control were added to the program, as well as electronic Subrack systems and IT solutions. The year 1985 was a real milestone, when the PS 4000 baying systems were developed. They were sold by the millions and became the new world standard. With Rittal the System to become the system provider With the introduction of the TS8 electronic enclosure in 1999, Rittal again set new industry standards. Today the TS 8, which has been sold 7.7 million times so far, and its infinite possibilities are the platform for Rittal The System, the solutions program still unique to the world: One single modular kit consisting of product solutions, engineering tools and services is able to create precision solutions for main power distribution, industrial automation, building installation, network technology and data centers. This completed Rittal s crossover from an enclosure manufacturer to a system solutions provider and substantially expanded its position as a world market leader. Worldwide market leader and champion of growth The power of innovation within the company has won many awards. Friedhelm Loh, son of the company s founder and owner of the Friedhelm Loh Group, received the renowned Diesel Medal in Numerous studies indicate the tremendous worldwide economic significance of the company. A current economic study in Manager Magazine 2010 ranks the Friedhelm Loh Group, which Rittal is part of, as the largest company in the Group, in place 80 among the most important German world market leaders. Furthermore, a study done by Accenture in 2011 includes the corporate group as part of the worldwide growth champions. Drivers of innovation Rittal is one of the companies that are molding the future. Their current and future endeavors include intelligent solutions for enclosure bases, energy saving cooling technology of the newest generation, as well as continued development for heat exchangers and software tools. With no end in sight, Rittal s expertise and innovations will, without doubt, bring another 50+ years of successes. 12

13 Like on the data highway: The goal is quickly within reach if there are no obstacles. The same applies for the design process. The process chain really gains momentum with new macros. It is not surprising then that the comprehensive master data packet especially designed for hydraulics users of the EPLAN Fluid demanded attention in the mechanical design. The new version revises standards for transparency and documentation, especially during interaction with the data packets. At the same time, this master data can be of solid assistance in the struggle against ever greater complexity. Full steam ahead EPLAN Fluid power: New master data packets force a new direction in mechanical design Pneumatics and electrical engineering on the same path The advantages of common documentation for steering technology in fluid and electrical engineering are obvious EPLAN Fluid is therefore often used together with EPLAN Electric P8. No more barriers to integrated processing of pneumatic and electrical documentation. Additional potential can be recognized when taking a look at hydraulics. Compare for example: Hydraulic design is often a part of the mechanical design. Large schematics up to DIN A0 format are typical. In the hydraulic industry, customer requirements and new standards increasingly specify structured documentation in DIN A3 or DIN A4 format. Requirements for convenience functions such as rotating and mirroring partial schematics or single components also differ from the documentation requirements in electrical engineering. Fluid data packet: 1,000 new macros Eplan has been working with well known manufacturers and users to support the special requirements of hydraulics. From the beginning, in the summer of 2010, EPLAN Fluid 2.0 offered users a comprehensive fluid data packet containing more than 1,000 hydraulic macros. The slogan is: by professionals for professionals. Because answers to the usual questions are important: What exactly has to be documented in the dayto-day hydraulic environment? What technical data must be included in the hydraulic schematic? What pressure switch settings are needed and how are they best represented in the schematic? EPLAN Fluid offers the best solutions for high-quality documentation with a combination of macros for pressure switches and the associated data tables. Hydraulic power units and sub-plates The tremendous number of filter variants and pump and motor combinations on power units often lead to very similar documentation that only vary slightly in the smallest detail. EPLAN technologies, such as variant technology and project options, offer the unique opportunity of creating intelligent macros that can be changed instantly in the fluid plan. A modular system makes it easy to create different variants of collective sub-plates. This system provides the easiest way to put together sections. Perfectly suited for mirroring and rotating The new macros collection is the ideal tool for intelligent rotating and mirroring of fluid power elements; this is a new functionality of the upcoming Eplan Fluid version 2.1. Background: In a schematic, it is often necessary to represent that cylinders move in opposite directions and correspondingly control them. Ideally, the user only has to design half the switch and completes the documentation using the new convenient functions for intelligent rotating and mirroring. The new macros are great for this purpose. They are the ideal starting point Since the release of Version 2.0 in the summer of 2010, the users receive a comprehensive Fluid data packet containing more than 1,000 hydraulic macros. for key users, as well as administrators, while providing quality assurance. Eplan Data Portal Interesting for manufacturers The macro collection is also the optimum starting point for fluid power engineering for hydraulic component manufacturers. Based on the underlying macros, you can allocate your item data and use EPLAN Data Portal to make the component data available to about 20,000 users. The perfect multiplier. While neutral macros available in EPLAN Fluid can be used for different manufacturers (1:N relationship), the item data in EPLAN Data Portal is associated with a specific macro (1:1 relationship); it provides a solid engineering basis when combined with additional documents such as technical data sheets, component photos and 2D and 3D data. Triple advantage as a secure base for project planning The combination of Eplan Fluid functionality and the new practical hydraulic macros contained in the Fluid data packets delivers unbeatable advantages for the hydraulic design engineer: high expectations for graphical documentation according to current standards, modular kits for subplates based on practical applications, hydraulic systems, sandwich arrangements, etc. and an ever- increasing number of device data from fluid power manufacturers in the EPLAN Data Portal. 13

14 Data continuity speeds up Implementing integrated engineering data backbone SPANGLER GmbH, located in Töging an der Altmühl (Upper Palatinate), designs the automation of sophisticated industrial systems and constructs the relevant enclosures. They have many interesting international reference projects such as Waste water treatment systems for Bahrain and Saudi Arabia and Bauxite treatment for Suriname. The company was looking for a new CAE system to standardize processes and reduce project times. Continuous growth demands process changes Spangler works together with leading system engineers and has access to extensive expertise in application technology. The strategy to specialize on demanding tasks turned into healthy growth for the company. Because of this growth, management decided to implement a new CAE system. Helmut Graspointner, who leads the company together with Hannelore Spangler stated: The systems that we design and build are becoming more and more complex. The percentage of international customers is also increasing. Around 50% of the systems we design are installed outside of Germany. We have also reached a size where the agenda for process standardization includes shortening processing times and making companywide use of the knowledge of each designer. Ideal combination for enclosure construction Spangler found the right solution in EPLAN. The introduction of EPLAN Electric P8 provided the prerequisite for mostly automated electrical design. For example, an extensive library of components makes designers work easier and desired reports, such as bills of materials, are available at the press of a button. Spangler installed an integrated engineering system that is ideally embedded in the entire IT landscape. Spangler especially appreciates the wide variety of individually customizable list report functions and the fact that the system thinks ahead and informs the designer about any errors or inconsistencies. This holds for threedimensional enclosure layouts as well as electrical design. Implementation planned in detail However implementation had to be well-planned before these benefits could be reaped. Rainer Meier and Johann Weiher took on the task of defining the requirements for a new, future-oriented ECAD. They first completed basic training courses at EPLAN and then developed a step-by-step plan that covered a one-year time period. One of the main tasks in the initial phase was to define the interfaces between EPLAN and the other IT solutions so they can centralize the databases. Working together with EPLAN Consulting, a connection to the KWP ERP system was created to support the business end. Continuous up to production PLC programming also uses the EPLAN Electric P8 assignment list as a starting point and the CNC machine for mechanical machining of housings is controlled directly from the EPLAN Platform. Enclosure manufacturing also benefits from the interface to Rittal s RiCAD-3D. This combination makes it possible to quickly create real 3D views of the planned enclosure. Transparency was also an important goal for the project managers. Almost every employee can use the viewing function to look at PDF documents. The system documentation is stored on an FTP server and can also be viewed by the customer. All data is continuously passed through from engineering to production. In the end, Spangler installed an integrated engineering system that is ideally embedded in the entire IT landscape. The EPLAN Platform is continually synchronized with the ERP system, so there are no inconsistencies between business and technical IT. 14

15 Aiming High with EPLAN Realizing faster turnaround times Polycontrols Technologies Inc. specializes in process control and flow measurement. Its strength is designing gas mixture systems for applications that require precise concentrations. With having customers like the US National Air and Space Administration, it was a good reason not to let obsolete design tools keep it earthbound. The company decided to switch to EPLAN Electric P8 and EPLAN Data Portal. Enhance productivity We needed a new electrical design software package that would allow us to become more focused on our design process, says engineering director Sylvain Desaulniers. We knew our efficiency in getting our projects to completion was often longer than planned and that our old CAD tool was slowing us down because of lack of accuracy in the information contained in the project documentation. Reproducing Venus Atmosphere in minutes Their top project is assisting NASA to design and build a system that tests the ability of the module for a planned Venus landing. They are developing a gas mixing system that will simulate the vacuum condition in which the components will be subjected to during flight through the Venus atmosphere. This consists of two free-standing cabinets connected to the chamber, one with the electrical equipment and one with a gas panel with the components. This will allow NASA engineers to reproduce Venus atmosphere within minutes. Optimizing design is major time-saver After adopting EPLAN, Polycontrols has been able to reduce project design time and eliminate common editing errors, leading to faster turnaround times. Many tasks have been automated, like device wiring and numbering, to save time and improve accuracy. Working in EPLAN has allowed them to remain competitive in their industry. The better way Design synergies enhanced by data-sharing among disciplines AGRAMKOW develops, manufactures and markets fluid-filling, testing and production line information systems for appliance and automotive industries around the world. At the insistence of the automotive industry, we have used EPLAN since 1993, and now it s the European standard, says Bjarn Lund, process department manager of AGRAMKOW Fluid Systems A/S of Sønderborg, Denmark. Automakers insisted on EPLAN Initially, we used two electrical design systems: EPLAN 5 and an AutoCAD package. In 2005, we began phasing out AutoCAD as we wanted to use the same design systems for both appliance and automotive products. Along with EPLAN, we started using SolidWorks for mechanical design, only using AutoCAD for the P&I Diagram. This setup was used for a number of years, but ultimately we wanted to align design systems so the components were given the same names and all charts used the same symbols and had a uniform structure, he adds. This has now been achieved by migration to the EPLAN Platform. Documents in one-tenth the time AGRAMKOW saw an opportunity to capture important benefits through data-sharing among design disciplines by centralizing key design functions on the EPLAN Platform. While the benefits are continuing to accrue, a key takeaway has been dramatically reduced time to produce highly accurate, machine-specific documentation packages for order fulfilment. What used to take 37 hours to produce can now be generated in only 3½ hours by using EPLAN s advanced automation features to create the drawings for both the P&ID and electrical content. 15

16 16 EPLAN DATA PORTAL More data, more manufacturers, more functionality Eagerly anticipated greeted with enthusiasm the highlight of our day-to-day operations. A number of new devices and manufacturer data expands Eplan Data Portal version 2.0 and higher. Users can look forward to significantly more performance in conjunction with the new EPLAN Platform. True expansions in selection, display and component searches make day-to-day business much easier and give extra power to project planning. A vehicle for progress New time-saving functions in the online portal make it considerably easier to select and use device data and components. It saves time and creates enthusiasm. The integration of much more manufacturer and device data promises significant practical benefits: A new portal member is Leuze electronic, manufacturer of optoelectronic sensors, who has integrated EPLAN macros of selected switchgears as well as many safety oriented sensors. Another innovation: Festo is now offering a selection of their pneumatic components. Mitsubishi Electric expands the list of new manufacturers with PLC data and converters. Dehn + Söhne expanded their program with lightening and surge suppressor components. But that s not all: ABB has updated its data and Phoenix Contact has restructured its already extensive range of products to the newest functionalities of EPLAN Electric P8. More and more functions The new manufacturer data along with numerous expansions in the portal functions promise productivity right from the start. One of the eagerly awaited highlights is the Unique ID which uniquely identifies an article in the EPLAN Data Portal. This ID allows data from the portal to be updated even if the local part number has changed. And if the manufacturer so desires, the device data can now be displayed and filtered according to regional availability. The user interface optimization has also shown significant impact. For example, it now has filter options that can be hidden. This can significantly speed up page loading times. The keyword is speed: Users can find components much faster now if criteria has not been specified correctly. A simple click on alternative search suggestions (similar terms) makes it easier to find components. Therefore typing mistakes are no longer an obstacle in finding components either. Quicker search, quicker results Data transparency has been improved with the new display of the number of articles per product group including all subgroups in the manufacturer s catalog. This makes it easy to select even from bulky catalogs time-consuming page turning is a thing of the past. Another highlight is the new accessory lists for users who use the optimized accessory management in Versions 2.0 via the data portal. Other new features: automatic download of function template macros, referenced parts that have already been completed for the mounting layout, and the life cycle status of previous and subsequent parts so that data is always up-to-date. Larsen & Tourbo is the first Indian manufacturer represented in the EPLAN Data Portal. In accordance with their slogan, it s all Maximum speed and easy search and find that is what EPLAN Data Portal is based on; it provides data to more than 120,000 devices. about imagineering, they have uploaded data for more than 1,000 products online, just as a first step, like protection devices for instance, relays & contactor, transformers, power capacitors, contractors, circuit breakers, etc. The next step to expansion is in the planning with drives and software starters. Configurators At upcoming fall trade fairs, Eplan will present fascinating solutions with integrated configurators, which are linked directly to the Eplan Data Portal. Users will be able to individually configure their devices using the manufacturers product configurators. Directly in the portal online and web-based. This integration goes far beyond providing existing device and component data; it is the next technological milestone in the development of the portal. Some examples are the integration of the Endress+Hauser product configurator, as well as Rittal Therm. Imprint Publisher: EPLAN Software & Service GmbH & Co. KG An der alten Ziegelei 2 D Monheim am Rhein Telefon: +49 (0) 21 73/ Telefax: +49 (0) 21 73/ info@eplan.de Layout: MEDIABRIDGES GmbH Agency for Corporate Communication Pictures: Eplan, MEDIABRIDGES, fotolia, istock etc.