More than ever, switchboard construction is in a state of fundamental revolutionary change. A host of new technological possibilities, rapidly changing customer requirements, high costs and pressure on prices with shorter deadlines are challenges that the industry can successfully master thanks to the perfect interplay between digitisation and automation.
After talking about the main objective of Kablator’s ecosystem of automated cabling machines and systems, i.e. to support the value chains and processes of the cabling industry in the best possible way, we discuss in this article the first step on which it will be necessary to invest time and resources to start this technological revolution.
How to achieve a highly automated electrical wiring process with maximum quality? By seamlessly linking design and production data. Let’s talk about the digitisation of electrical cabinets.
Digitising the switchboard
Digitisation has now successfully entered almost all mechanical and production processes, consolidating integrated processes involving the exchange of electronic data across different sectors.
The company-wide support of interoperability and the use of data in design and production processes multiplies productivity, flexibility and competitiveness. This is now certain.
Consequently, it has led to a significant increase in the recognition of the importance of electrical engineering and automation capabilities.
One concept that is emerging as a fundamental pillar of this transformation is the digitisation of switchboard design via Digital Twin.
Digital Twin in switchboards
The concept of the Digital Twin applied to the switchboard coincides with 3D design, i.e. the realisation of the virtual replica that allows operations to be simulated, predicted and optimised using data and algorithms.
Designing switchgear and control panels using 3D is advantageous in a direct and sustainable way because by taking full advantage of the functionality offered by intelligent ECAD systems, complete and verified documentation is created.
If this engineering data is then made available throughout the company via standard interfaces, numerous advantages are achieved.
The first step, therefore, is the acceptance of the initial costs and efforts of creating the ECAD component database and the necessary libraries with all the technical details to digitise the documentation.
This first step will eliminate many tasks previously performed manually using printed documentation. This requires a standardisation concept with the appropriate design templates.
The more complete the dataset of information attributed to each component, the more the entire process can be automated. Geometries, dissipated powers, installation constraints, codes, drawings, specifications for each component can be shared via exchange files with production equipment and simulation software to optimise the design from a dimensional and functional point of view.
Benefits of digitising electrical design
The benefits are manifold:
Time: the time spent on design will pay for itself in large part through the benefits obtained in the engineering, construction and maintenance phases, before investing further time and resources. There is a significant reduction in project cycle time;
Resources: significant reduction in resources employed and therefore lower costs;
Quality: high and consistent. The digitisation process enables efficient storage and accurate analysis of data, reducing the time spent on information management and improving the quality of the maintenance service;
Productivity: doubling the productivity of projects and thus reducing opportunity costs for projects not pursued;
Flexibility: productive and planning flexibility. Allows you to respond quickly to customer needs even at short notice.
How to start a digitisation process in switchboard design
In order to start a digitisation process of the design, it is necessary to have a technical office where the development team can structure the designs using ECAD level software.
In such a way that all functionalities can be utilised, including control routines that detect anomalies in the circuit diagram in order to generate reliable lists and overviews culminating in a graphical visualisation of the board.
If these skills are not available in your own company, you will need to rely on those who perform this service professionally on behalf of third parties.
At Kablator we have developed an ad hoc service for our customers, the DIGI SCHEMA, which makes it possible to make up for the lack of design engineers in your company because it performs all the activities of digitising the circuit diagram to obtain a data set suitable for production automation.
Thanks to the structuring of the source data, there will be considerable time savings in all subsequent stages of switchboard construction.
The digital twin produces all the necessary data for sheet metal production, as well as all the data required for cutting cable ducts, terminals, rails and terminal blocks. Functional parts that are used on a regular basis could thus be pre-produced in small batches and kept in stock, or supplied just in time at the start of each new job very quickly.
Just as all wire and conductor data can be passed directly to the automatic wire preparation machines. Prepared wires simplify and speed up the next wiring phase, which is usually the most time-consuming. Just as the indication of components and connection points on the cable saves employees time-consuming searching in the circuit diagram.
Historical wiring diagram project database
It should also be borne in mind that in many cases the projects to be developed even if they are individual are by no means unique. Most of them are a variation of previous ones with differences of up to 80 per cent. In this case, having a digitised design process with electronically accessible documentation can add a huge advantage. Once the wiring diagram of a similar system has been digitised, it can be copied and modified.
Another advantage is the flexibility of last-minute changes. Digitised processes offer flexibility and allow customer requirements to be implemented right up to just before the shipment itself because they are connected to the entire production system.
We have therefore seen a quick overview confirming that digital wiring data accelerates the switchboard construction process in all its phases.
If your switchboard company needs advice in this area, Kablator is able to respond fully through a customised switchboard digitisation process.
For a Kablator technology consultation:
+39 3313466711- info@kablator.com
