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    Archive for category: Success Stories

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    RWE: On the grid with a double-walled design

    RWE intelligent modular enclosure

    For decades, open-air supply cabinets have been performing a vital service in the 380, 220 and 110 kV substations of the RWE transport and distribution network. However, due to the cost of corrosion protection and problems with the interior climate of the single-walled sheet steel enclosures, it was time to find a new solution.

    “The concept presented by Rittal and SSS met our requirements and turned out to be the optimum solution based on an analysis of commercial and technical benefits.” Dr. Ulrich Küchler, Head of Primary Technology, RWE Westfalen-Weser-Ems Netzservice GmbH

    Investing in the future

    Stringent requirements were set out for the new enclosures, which would have to exhibit improved internal climatic conditions, offer corrosion resistance for over 40 years, be compatible with existing modules and be comprised of standard modules. Together, Rittal and Essen-based control unit manufacturer SSS Elektrotechnische Systeme presented a solution based on these demands. By combining Toptec outdoor enclosures from Rittal with the RWE intelligent modular design that has been tried and tested over the course of several decades, the partners developed a concept that RWE had made a compulsory requirement in early 2010.

    Close to the standard but still flexible

    The collaboration between RWE, SSS and Rittal culminated in a series product based on Toptec that can be delivered quickly. However, it had also been tailored to RWE in terms of its technical specifications and boasted exceptional flexibility in terms of accommodating a range of local conditions.

    The power of two walls

    The stainless steel base frame of the enclosure is based on the TS 8 system platform, while the doors, side components and roof are made from aluminium, which results in a weight saving of up to 40 percent. The double-walled design ensures better climatic conditions inside the enclosure and helps to prevent condensation. Despite these many benefits, the new solution costs no more than the single-walled variant.

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    Kassel Rural District: Broadband expansion in Rittal outdoor enclosures

    Outdoor Enclosure

    High speeds are the order of the day on Germany’s information highways – especially after a network expansion. The German Federal Association of Broadband Communication estimates that households in Germany will be surfing the net at average transfer speeds of 200 Mb per second by 2020 at the latest. In rural areas in particular, large sums are currently being invested. In 2012, the rural district of Kassel connected 74 areas in 23 municipalities to the DSL network.

    “We took delivery of enclosures that had been prepared precisely to our requirements”
    Klaus Peter von Friedeburg, Managing Director of ACO Computerservice GmbH, Kassel

    Rittal supplied more than 150 outdoor enclosures that had been specially customised for their intended use. The technology inside links the signals arriving by glass fibre cable or microwave radio relay to Deutsche Telekom’s existing copper lines.

    Coping with heat

    To stop the multifunctional enclosures from overheating, Rittal chose an entirely double-walled construction and incorporated vent slots close to the ground and under the enclosure roof. When the outer skin heats up, the air in the cavity between the two aluminium sheets also gets warmer, which causes it to rise up, creating a vacuum effect and drawing in cool air from close to the ground. This thermal flow provides extremely effective cooling in a natural – and completely free – process.

    Extending service life

    Keeping temperatures under control helps to extend the service life of the electronics and, more importantly, safeguards availability. That is particularly important when the outdoor enclosures are located along radio relay lines in the middle of the forest and are therefore very difficult to reach. However, the stringent requirements for failsafe operation are not restricted to simply withstanding extreme temperatures. When positioned close to roads, the compact units can be exposed to very different immediate and long-term hazards. For example, Rittal uses a special coating made from pure polyester to protect the units from salt spray during winter.

    Protection from traffic accidents and vandalism

    Taking into account the risk of traffic accidents, Rittal designed the total of 150 enclosures installed in Kassel so that they can be repaired or the outer enclosure even completely replaced without having to switch off the communications technology inside. “When an excavator bent a door completely out of shape while it was being installed, we were able to see for ourselves how quickly and easily repairs could be carried out. A replacement was available immediately and Rittal’s service team arrived at the scene promptly,” says ACO Key Account Manager Stefan Finger. The enclosures have also been built to meet resistance class 2 and therefore offer adequate protection against vandalism.

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    Littau GmbH: Upgraded to a research vessel

    Originally built in 1981, the fisheries protection vessel Seefalke was transformed into one of the world’s most state-of-the-art research ships in the space of just two years. Littau, a switchgear engineering company that specialises in industrial and shipbuilding applications, was responsible for fitting out the heart of the ship – its new main switchboard – and opted once again for enclosure technology from Rittal.

    “We have been using solutions from Rittal for quite some time due to the high quality of its products. The difference in quality standard is most apparent on the upper deck, where Rittal enclosures stand alongside competitors’ products and are exposed to harsh weather conditions.”
    Kai Töllner, Sales Manager at Littau

    Secure switching system

    At 7.20 metres in length, the main switchboard controls the power supply throughout the entire ship from one place. Two diesel generators feed power to busbars in the main switchboard, where it is then distributed to the various consumers in the ship. The system features a total of 12 sections that are each assigned to certain consumers. Every section incorporates Rittal TS 8 enclosures, which come with GL (Germanischer Lloyd) certification as standard, and Maxi-PLS power distribution technology from Rittal.

    Flexible through and through

    The core of the TS 8 is the 16x folded vertical section of the frame, which delivers excellent stability and also offers a second mounting level and thus diverse configuration options thanks to a comprehensive range of system accessories. The excellent flexibility of the enclosure solution also extends to the Ri4Power power distribution system from Rittal. Indeed, the connection-friendly system offers numerous advantages for power infeed, where a multitude of cables converge.

    Packed with Rittal

    In addition to the large enclosures, the entire ship – from the engine room via the decks to the bridge – is packed with compact and small enclosures. For example, there are several compact enclosures in the engine room that house the control technology for the ventilation, fire dampers, rudder hydraulics and waste incinerator. More than 80 percent of the enclosures on board – almost 100 – are from Rittal.

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    Daimler: Rittal climate-control systems reduce energy consumption by up to 70 percent

    While searching for ways to boost energy efficiency, Daimler put energy-saving cooling units from Rittal through their paces in live tests. The Sindelfingen plant manufactures products including pressed parts for Mercedes-Benz and Maybach. And the enclosure cooling units from Rittal ticked all the boxes.

    “The test results convincingly showed that Rittal’s Blue e generation cooling units would enable us to achieve clear energy savings.”
    Harald Bölle, Head of Industrial and Building Systems – Electrics at Daimler AG in Sindelfingen.

    Up to 70 percent lower energy consumption

    The major potential for improvement is primarily related to the main energy consumers – the coating and press plants. The latter, for example, consumes 40,000 MWh/a. In view of the unequivocal test results from a pilot application, Daimler AG decided to replace the old cooling units with new ones as soon as possible and to convert all switchgear at the press plant by 2012. The automotive manufacturer placed an order for more than 250 new units with outputs from 500 W to 2,000 W – even before the cooling units were officially available.

    Saving on running costs and lowering environmental impact

    It is a blessing for budget planning. By changing its cooling units, Daimler can save operating costs running into six figures and satisfy its claim of “Green Technology Leadership”. In total, the new climate-control systems will stop almost 500 metric tons of CO2 from being released into the environment each year.

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    FrieslandCampina: Hygienic Design allows process-oriented automation

    In dairy enterprises, pneumatic valves ensure that networked systems consisting of pipes, heaters and stainless steel tanks work precisely. Up to now, pneumatic actuators have been controlled by valve islands installed for reasons of technical cleanliness, and which were kept in standardised stainless steel enclosures located at a safe distance from the actual application. The new AirLINE Quick valve islands from fluid control system provider Bürkert, which are installed in Rittal Hygienic Design enclosures, now offer a number of benefits.

    “Pneumatic enclosures so close to the process took some getting used to at first. However, we noticed a long time ago that these necessary cleaning procedures are really not a problem!”
    Tim Borgstaedt, dairy master at FrieslandCampina

    Ready for automation in the midst of the hygienic environment

    With the valve island, the need was for fast installation and the highest operational reliability. The new automation system was technically optimised for hygiene through the clever combination with stainless steel enclosures from Rittal’s Hygienic Design series. These HD enclosures, tailored to the high hygienic standards of the food industry, can be easily cleaned. Through the symbiosis of the AirLINE Quick with the HD modular system a complete solution is now available that can actually be used within a hygienic environment in a dairy or brewery.

    Advantages of the “on-site” system

    This solution offers users short distances to actuators and sensors, far shorter times and reduced costs for installing pneumatic hoses and control cables, the quick detection of any possible hose leaks, better monitoring and maintenance of the overall system, low air consumption, as well as substantial improvements in the hygiene of the entire system.

    The innovation also shows its strengths in terms of costbenefit ratio: In many cases, the extra costs of the new “local” system can be offset by the savings of hundreds of metres of hose and cable.

    Use at FrieslandCampina

    Installing the system at a new dessert and yoghurt line at FrieslandCampina in Gutersloh represents a reference project. The process valve nodes that control which medium is currently being moved and in which dosage, are regulated by 42 HD enclosures, each with two 24-fold AirLINE Quick valve islands, including digital feedback inputs.

    The bulk of the pneumatic enclosures are lined – in rank and file – next to the valve nodes, so they installed right in the middle of the hygiene-sensitive process field.

    Where once 20, 30 or even 50 metres would have been necessary, now just five metres are sometimes enough to get from the enclosure to the actuator or sensor in this improved installation option.

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    Celler Land Geflügel: Hygienic protection of the control electronics

    Every day, more than 500,000 packages of fresh chicken leave the two slaughterhouses and cutting plants at Landgeflügel. The highest standards of hygiene have to be adhered to when preparing fresh poultry. Hygienic Design enclosures from Rittal offer protection for the sensitive control electronics during the daily cleaning and disinfection of the system components.

    “Our experience has been so positive that we chose HD enclosures across the board when fitting out the new site at Wietze.”
    Fabian Thölke, Head of Maintenance at Celler Land Frischgeflügel

    Hygienic Design enclosures at the centre of the process field

    Hygienic Design enclosures (HD) from Rittal, specially designed to meet the hygiene requirements of the foodstuff sector, offer Landgeflügel added product and process safety in the production process: Made of stainless steel and with a sloping roof, they can be cleaned without leaving behind any residues. The hallmark of the HD is its blue, external silicone gasket. It seals without leaving any gaps, so protecting the electronic components installed in the enclosure from penetrating water.

    Enclosures stand up to being cleaned every day

    The Hygienic Design enclosures made their debut in some parts of the production system at Emsland Frischgeflügel. At the headquarters of Landgeflügel, which was opened in 2003, individual enclosures were first tested in running operation. What really mattered was that the test enclosures withstood being cleaned every day. Porous gaskets and leaks that had occurred over and over again in earlier enclosure solutions, and which caused damage to the sensitive control electronics, no longer occurred with the HD range.

    Use in the conveyor belt and packaging fields

    The main application field of the HD enclosures at the Wietze site are the conveyor belts, several kilometres long, which ensure the precisely timed transport or the exact outward transfer of the various chicken products following the complex cutting processes.
    The enclosures also represent a key constant in the packaging area, which consists of eight different lines.

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    W. Althaus AG: Automation in panel building and switchgear construction

    There is still much room for improvement in panel building and switchgear construction. W. Althaus AG, based in Switzerland, has scrutinised and automated every process as far as possible. What made their strategy so successful was the consistency of the data along the entire process chain – from engineering, through production and up to including testing. Rittal systems were instrumental in supporting W. Althaus AG because they helped to ensure maximum data availability.

    “Due to the additional optimisation opportunities along the process chain, we have achieved an efficiency gain of around 20% in production alone over the last two to three years.”
    Walter Althaus, owner of W. Althaus AG

    Completeness of data is paramount

    In hardware engineering, the solution is first developed that is used to ideally implement the customer’s requirements. Electrical planning is performed using Eplan’s Electric P8.

    Following electrical planning, the experts at W. Althaus AG create a virtual prototype enclosure in Eplan Pro Panel. The quality of the prototype depends largely on the availability of data for all the components used. This data must also include mechanical dimensions, electrical connections and commercial information. The data can be downloaded most easily from the Eplan Data Portal, which currently includes around 480,000 article and device data records from over 60 well-known manufacturers, directly into the local Eplan database at Althaus. Rittal systems are part of that. Control and switchgear systems can be made standardised and modular with enclosure systems from Rittal.

    Direct control, using engineering data

    Today, panel building and switchgear production are usually still characterised by a great deal of manual work. However, at W. Althaus AG, the highest possible degree of automation was also sought in production. Routing for the cable assembly is realized directly in Eplan Pro Panel, for instance.

    Automated assembly of terminals

    In addition to cable assembly and metal processing, the mounting of terminals on top hat rails is another labour-intensive production step. This was the reason behind the idea of automating placement of the terminals on top hat rails, which culminated in the Athex terminal assembly machine. The assembly machine may accommodate up to 6,000 terminals, depending on the equipment, and mounts these on top hat rails automatically. It can even label terminals directly. The Cutex cutting machine complements the assembly machine ideally. It can cut top hat rails automatically to the proper length and directly label them.

    In turn, both machines can work directly with the data from the Eplan project. The combined use of the two automated machines can greatly reduce the number of manual working stages in this segment of switchgear manufacture. Althaus’ owner estimates that the company can increase productivity by as much as 50% when describing the potential benefits offered by automated assembly.

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    MWB Maritime Technology GmbH: Rittal enclosure and rack technology on MS Ostfriesland

    MS Ostfriesland has linked Emden to Borkum for around 30 years. In summer 2015, the ferry switched from steam to liquid gas. This was preceded by extensive modification work and a high investment. As this process involved integrating considerably more technology, MWB Maritime Technology GmbH turned tot he comprehensive „Rittal – The System.“ range for enclosure technology.

    Just the job at sea – with standard solutions

    The radical changeover in drive technology and integration of a liquid gas supply resulted in the control and monitoring technology assuming much greater importance during the switchover. Fitting all this into the space available was a challenging task for the MWB project team. Individual adaptations had to be made to the contours of an existing vessel. The order from shipping company AG EMS also specified that although the space gained by extending the ferry by 15 metres should be used for the liquid gas tank and gas control technology installed in Rittal enclosures, it should also ensure greater passenger comfort as far as possible. All enclosures for the complete automation of the ferry thus needed to be designed as flexibly as possible, without having to rely on costly special solutions.

    Rittal solutions from rack to control panel

    Racks from the Rittal TS IT series are now installed on the bridge. These are specially adapted enclosures for installing network components and communication and control technology. Integrated into the door, are operating units and screens for displaying status reports and operating statuses. The TS IT system can thus be flexibly adapted in such a way that the doors are fully available for operation and monitoring. The racks are also ideal on MS Ostfriesland due to their robust construction and high load-bearing capacity. Thanks to the versatile interior fitting options, MWB was able to use standard components for rapid installation and cable management when integrating the technology.

    This system approach can also be found in the main switchboard of MS Ostfriesland, where enclosures from the Rittal Ri4Power series were used to install the main supply. Here, too, MWB was able to rely on the Rittal system range during the installation of the main switch-board and emergency power supply, particularly in the form of busbars, connection components and contact hazard protection.

    Everything at a glance

    A third representative of the Rittal system shapes the situation below deck in the engine control room. To ensure crew members have an overview of all the ferry’s functions, large touchscreen monitors are integrated into the Rittal TopConsole (TP) system. The spatial constraints prompted MWB to integrate MS Ostfriesland’s other installation technology into compact CM and AE enclosures and use wall mounting to position the enclosures in locations on the ferry where space was still available, without impeding access or impairing passenger comfort.

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    KUKA Industries: Magnetarc welding machines come with Rittal TS 8 enclosures

    Magnetarc welding machines from KUKA Industries deliver unparalleled precision and exceptional weld quality. The electrical and electronic components of these state-of-the-art processing systems are housed in Rittal TS 8 enclosures.

    “Having an enclosure that’s deployable anywhere means we don’t have to custom-engineer each unit to specific requirements. And that reduces our production costs.” Robert Hummel, Electrical Design, KUKA Industries

    TS 8 deployed from the start

    KUKA Industries has employed TS 8 enclosures with the Magnetarc ever since its launch in 1999. The feature that sealed the deal was the TS 8 system’s symmetrical design in every dimension, offering unlimited scope for extension. Enclosures can easily be added to a bayed suite as needed

    TS 8 – the established standard

    KUKA Industries is a supplier to the automotive sector, so all components must fulfil very high quality standards. Every part used in production processes is validated. Leading carmakers have adopted Rittal’s TS 8 enclosure system as standard in all their plants, which is of major benefit to KUKA Industries. It affords the manufacturer greater access to worldwide markets, and also creates cost efficiencies. Prefabricated subassemblies and Eplan design software simplify and accelerate the planning and engineering of enclosures – including Rittal cooling units and command panel solutions.

    Rapid after-sales service worldwide

    Welding machines from KUKA Industries are deployed worldwide, so a component supplier with matching capabilities and reach is a must. Rittal markets its extremely popular TS 8 enclosure system through 58 international subsidiaries. Products can be delivered at short notice from some 90 warehouse locations.

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    Ripploh: Quicker switchgear construction

    Efficiency is still a top priority in panel building and switchgear design, and there is still potential waiting to be tapped throughout the entire value chain: from engineering to production, to machining and equipping an enclosure.

    “Our employees no longer have to rethink on permanent basis, and that cuts out a huge source of errors with knock-on effects.” Andreas Ripploh, Managing Partner of Ripploh Elektrotechnik GmbH

    Users need engineering solutions that help to draw up electrical plans and documentation in an essentially automated process. They need enclosures that are based on a uniform system platform, that suit various applications and that minimise potential error sources and installation time. Ripploh Elektrotechnik GmbH, based in Ostbevern, have pioneered the use of such solutions.

    Rapid planning by configurator

    As the backbone of the project planning, the plant constructor uses a virtual modular component kit, which is stored in the Eplan Engineering Centers (EEC). “We make no more customer tenders, because they use the Configurator to choose the assemblies, which are available at a fixed price,” Andreas Ripploh, Managing Partner of Ripploh Elektrotechnik GmbH, said.

    A uniform enclosure platform

    The choice of the right enclosure system is also important to Ripploh so that the maximum level of efficiency in production can be achieved. It is advantageous when switchgear projects (across all industry sectors with very different requirements) can be implemented with one single enclosure system platform. Ripploh has been using housing and enclosure system from Rittal since 1995 to achieve this due to the tangible benefits that consistent internal enclosure installation offer: A variety of expansion options can be implemented quickly and easily in various sizes of enclosures with the uniform TS 8 system platform and its matching accessories; if necessary, a choice can be made between different types of enclosure.

    Huge source of errors cut out

    Since Rittal has “docked” its new SE 8 enclosure system to its existing TS 8 platform, these now offer the same configuration options as traditional baying systems. “The new SE 8 enclosure is very beneficial for us, because we can use the same accessories for standalone applications as with the TS 8 bayed enclosures,” Andreas Ripploh explained. “Our employees no longer have to rethink on permanent basis, and that cuts out a huge source of errors with knock-on effects, starting with the order itself and continuing through assembly until the delayed delivery.”

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