Smart Wiring for Electrical Panel Design Engineering & Maintenance. Hermann Wagner Application Engineer EPLAN Software & Service

Transcription

1 Smart Wiring for Electrical Panel Design Engineering & Maintenance Hermann Wagner Application Engineer EPLAN Software & Service

2 The Process Chain in Panel Building Total process machine builder with integrated control cabinet manufacturing From the 1 st page of the circuit diagram Until operation at the end customer Electrical engineering Engineering Production Operation Provides the planning documents, circuit diagrams, mounting drawings,... Control Cabinet Planning / Production Complete production and assembly + internal electrical testing and delivery to the end customer Operation at the installation site 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.

3 The Process Chain in Panel Building Projecting Phase Circuit Diagram Creation Circuit Diagram Customer / Engineering Total process machine builder with integrated control cabinet manufacturing Circuit diagram BOM Wiring list Mounting layout (schematic) Technical specifications These activities Engineering 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 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. Operation Production Based on the documents and data provided by Customer / Engineering.

4 The Process Chain in Panel Building Electrical-Engineering Specification Conditions Hardware Design Schematic Design Check Schematic Generate Documents Clarification of functional requirements Clarification of installation conditions Delivery specifications Functions Technical design Working in CAE Last corrections Review and approve data Generate manufacturing documentation

5 The Process Chain in Panel Building Production Cabinet Planning Commissioning Mechanical Processing Pre Assembling Installation Wiring Test Check data from customer/ engineering and integrated into the system and processes Mechanical NC data Electrical 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 crosssections Control wire cross-sections Error checking Setting parameters Test reports In-house function test Routing 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.

6 EPLAN Smart Wiring The virtual planning of the control cabinet is a prerequisite for the delivery of standardized manufacturing documents and data.

7 The Process Chain in Panel Building Case study of potentials in the process chain Framework: 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

8 The Process Chain in Panel Building Case study (Process-time distribution) Manufacturing Times 22% 10% 4% 2%4% 4% 6% 5% 43% 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

9 The Process Chain in Panel Building Case study (Process-time distribution and potentials) Potentials Testing Installation on mountig plate and door Marking Cut to size DIN rails and wire-ducts Optimized Today To raise the potential in each area, the appropriate conditions must be created in the engineering

10 Potentials in the Process Chain Potentials in manufacturing 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

11 Potentials in the Process Chain Potential through the use of wiring lists 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

12 EPLAN Smart Wiring With support from EPLAN solutions digital data e.g. for wiring can be deployed, including step by step instructions for manufacturing.

13 EPLAN Smart Wiring 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 The software-based support for the manual activities in manufacturing allows better scalability of capacity and resources.

14 EPLAN Smart Wiring Software based support for the panel shop

15 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

16 EPLAN Smart Wiring Workflow EPLAN EPDZ-File E-CAD MS Excel File

17 Software Presentation

18 EPLAN Contact Information Hermann Wagner Application Engineer EPLAN Software & Service 425 N Martingale Road Suite 470 Schaumburg, IL USA (847) info@eplanusa.com