Efficiency in the Engineering Process
21 May 2021
The Interplay of Systems and Products

Time and cost pressures are important factors in switchgear manufacturing that drive the entire process, from planning to maintenance, and demand constant optimization of all work processes. Viewing process steps in isolation squanders potential efficiency gains. Making processes as efficient as possible requires an integrated approach to systems and products, taking all phases, from planning and engineering to implementation, testing and commissioning, into consideration.

The technical demands on the process of designing machines or buildings have long been high; due to greater networking of systems – as well as other developments we cannot necessarily foresee – these demands will only increase. While the requires on automation and switching elements of machines and systems themselves continue to increase, the demands for ever shorter delivery times, falling costs and the growing shortage of skilled labor are also creating challenges for mechanical engineering. Remaining competitive and cost-effective while these resources become scarcer requires sophisticated, efficient processes throughout the whole value chain. Manufacturers need to develop products and systems that are designed for the entire process chain.

The Key Information a Glance:

Efficiency in the engineering process saves time and money.
Data consistency: Product CAE data should be provided in the best possible form.
Bidirectional interaction: Manufacturers’ systems need to provide suitable interfaces to leading systems.
Terminal block marking: Exhaust the possibilities and save time on documentation.
Installation: Rail-mount terminal blocks should be especially easy to handle.

Now if I want to provide documentation for a switchgear unit, I also need all the data from [...] two dozen manufacturers in the correct form.

Frank Sellke, Business Development Manager at WAGO

The Core of the Process: Data Consistency

Switchgear design and engineering have incorporated digitization for quite some time – that’s nothing new. CAE systems, such as EPLAN or WSCAD, have become established for project planning of circuit diagrams and systems. “As a manufacturer, we need to be able to interface with these providers’ solutions,” says Frank Sellke, Business Development Manager at WAGO. “There are at least two dozen different manufacturers that are relevant for switchgear units, including drive technology. Now if I want to provide documentation for a switchgear unit, I also need all the data from these two dozen manufacturers in the correct form. In the end, all the components and devices need to have exactly as much space in reality as is specified for them virtually, after all. So we have to be sure to provide data for our products in the best possible form.”

The data provided for the products is not only useful for comprehensive project planning: If you have a good digital image of the control cabinet or distribution box you’re developing, you can use simulations – for example, you can do virtual testing in advance to determine how warm a system will get and whether additional air-conditioning is needed. That lets you identify potential stumbling blocks at the beginning of the process chain; eliminating them early on saves time and conserves resources throughout the value chain. “So every manufacturer needs to provide much more data on their products, in addition to size, color and weight, so these specialized tool elements for simulation can work cleanly and reliably too,” continues Sellke.

Bidirectional Interplay – Leading Systems and Manufacturer-Specific Tools

The interplay between manufacturers and system providers is not only based on maintaining and providing technical data for the products. Manufacturer-specific tools also need to be able to exchange their data automatically with leading systems for further process optimization. “The better this works bidirectionally, the more sense it makes,” says Sellke. One example: End plates for rail-mount terminal blocks are not electrically relevant at first, so standard tools don’t show them in the circuit diagram. However, they ensure that electricity conductive metal surfaces that people can come into contact with are safely covered – so they are still needed.

“Now you can do exactly that in the WAGO Smart Designer configurator. First you import the pre-defined terminal strip. The terminal blocks are then lined up one after the other on the DIN-rail and undergo a plausibility check,” says Sellke, explaining an important feature of the 3D online configurator. The program has interfaces to various CAE tools, allowing easy incorporation of existing electrotechnical design status information.

If they are missing the end plates mentioned above or other important accessories, these are automatically added to complete the terminal strip. To get a complete parts list at the end, it is necessary to feed this result back into the leading system via the available interfaces. What initially looks like an additional process step is – if the two systems interact well – a useful design check that ensures completeness of the parts lists and prevents possible delays during assembly due to missing accessories.

Making Better Use of Marking Options

Using manufacturer-specific tools also makes sense for efficient “handoff” between different process steps. For example, taking terminal strip marking into account during the design phase already and passing this information on to the installer via suitable systems and interfaces eliminates a time-consuming intermediate step, and work processes can continue smoothly without the need to intervene. And there are other reasons why it makes sense to take a look at the systems. Continuing with the example of marking: First of all, tools eliminate the need for manual transfer from leading CAE systems to other systems (such as Excel), since the manufacturers’ tools are often equipped with the appropriate interfaces. Secondly, it is worth taking a look at the advanced options these tools offer.

“The marking options many CAE tools offer don’t necessarily exhaust all the options that already exist to add value for the customer,” says Sellke. For example, instead of assigning terminals to only one number, WAGO’s Smart Designer allows automatic creation of marking strips with up to three lines, making it possible to fit significantly more information on a strip. This allows on-site users to more quickly determine which signal is applied at a specific location and which function the terminal blocks are intended for. “This may even make additional documentation mostly superfluous, since the terminal strip marking gives enough hints and information for you to find your way around,” says Sellke in conclusion. “That makes the wiring work easier and saves a lot of time during maintenance later.”

User-Centric Installation

The process of providing data and the sensible interaction among various systems and tools are currently hot topics – also for automated processes, which are becoming more and more intelligent. But at the same time, manufacturers such as WAGO are working to make the handling and design of the products themselves more efficient. The development of the TOPJOB® S Rail-Mount Terminal Block series has followed various market trends and demands in recent years. “In control cabinet manufacturing, actuation with a tool is very common,” says Sellke. “However, in our experience, a lot of wiring work still happens in the field, where having the right tool at hand is not always guaranteed. That’s why our terminal blocks are also designed not to require a specific matching tool.”

For this reason, WAGO has also equipped its line of rail-mounted terminal blocks – which offer the additional option of directly connecting solid conductors and conductors with ferrules – with a push-button and lever actuation variant. “With the lever version, we actually have a terminal block that no longer requires the on-site installer to have any tools at all, and the lever visually indicates the connections that have to be made,” says Sellke. “That eliminates errors and makes installation faster.”

Conclusion

Increasing efficiency is crucial for cost-effective, competitive switchgear manufacturing. The greatest potential for optimization comes from the interplay between all the factors involved in the value chain. An efficient engineering process requires an integrated approach to processes, products and systems that takes everything, from planning to installation and maintenance, into consideration. Data provision and bidirectional data exchange are at the top of the list, along with user-centric products and tools. The benefit: The overall process is faster and requires fewer resources.

Push Performance to the Top Easily with TOPJOB^® S Rail-Mount Terminal Blocks

Whether in industrial applications or modern building installations, WAGO’s TOPJOB® S Rail-Mount Terminal Blocks offer more than just reliable electrical connections. The comprehensive line of through and function terminal blocks for conductor cross-sections from 0.14 to 25 mm² (26–4 AWG) offers a variety of advantages.

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Efficiency in the Engineering Process 21 May 2021 The Interplay of Systems and Products