Efficient terminal strip construction and mounting
Control cabinet builders face challenges in cost-effectiveness due to rising costs and a shortage of skilled workers. This article covers the production and mounting process of a terminal strip, from digital construction to marking and mounting, highlighting efficiency solutions for each step.
Despite increased automation in control cabinet building, mounting tasks are mainly manual. Automation is mostly used for material and work preparation, such as preparing the mounting panel and housing, cutting cable ducts and DIN rails, and preassembling wires. Manual tasks include picking components, mounting, wiring, and testing, usually done on the installed mounting panel by a qualified specialist.
To solve these problems, mounting processes must be thoroughly analyzed. The first step is shifting from direct mounting in the control cabinet to upstream module mounting.
Software-supported DIN rail assembly with worker assistance systems
In upstream module mounting, the DIN rail is fully assembled before installation in the control cabinet. Digital preparation of diagrams and optimized workstations with worker assistance systems enhance efficiency.
Data consistency from engineering to production underpins these systems. For instance, most ECAD systems can export data to engineering software like clipx Engineer from Phoenix Contact. Consequently, this software centralizes all components, functions, and marking information, ensuring a seamless digital workflow and eliminating paper-based media discontinuities. Furthermore, the worker assistance software provides only the necessary information for each production step, avoiding extensive documentation searches.
Efficiency can be further increased by using a workstation with an interactive worker assistance system and a pick-by-light system. Controlled by the software, it displays the correct shelf section for each mounting step, guiding the employee through the process. This reduces search times and errors, significantly boosting efficiency, and allows semi-skilled workers to perform mounting tasks.
Marking requirements
After assembling the DIN rail, it is marked for clear, permanent identification, enhancing safety and workflow efficiency. Uniform marking of components can save up to 30% of production time. Phoenix Contact offers a comprehensive range of marking solutions, including versatile materials and intuitive systems, supporting various technologies like thermal transfer, UV inkjet, and laser marking.
Simplifying the identification process with the aid of worker assistance systems
The construction and identification of a DIN rail involve various components and project variations. The worker assistance system simplifies selecting, creating, and mounting markings by using information from the engineering software, preventing errors. Employees use marking software to choose the right marking systems and materials, which are then printed. The system guides users step-by-step in applying the markings, reducing errors and enabling semi-skilled workers to handle complex projects.
Efficient mounting of terminal strips
After constructing and marking the terminal strip, it is mounted in the control cabinet. The challenge is that the elongated holes of the DIN rail are often inaccessible due to mounted components, making it difficult to secure the rail. This has led many builders to prefer the classic method of attaching the DIN rail first and then adding components.
Current methods to mount terminal strips include:
- Leaving spaces for fixing points, which reduces the rail’s capacity.
- Removing and remounting components around fixing points, which is time-consuming and poses a quality risk if components are not correctly repositioned.
Railfix adapters from Phoenix Contact simplify mounting fully assembled terminal strips without front access to elongated holes. The adapters are pre-mounted on the panel, and the DIN rail is placed into the locking clips with guide elements. Using a screwdriver, the rail is levered under the clips and secured with an M5 screw.
The mounting distances of Railfix adapters depend on the DIN rail pitch and the load from mounted components. The zinc die-cast adapters are electrically conductive, allowing shield currents to discharge to the mounting panel.
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