Electrical Control Panel Design and

Fabrication

A Seminar Report
Submitted in partial fulfilment of the
requirement for the award of the degree of

Bachelor of Technology in Mechatronics

Engineering

Sarthak Saxena

149129140

(Department of Mechatronics)
MANIPAL UNIVERSITY JAIPUR
 ACKNOWLEDGEMENT

To
Prof. Varun Jurwall

To Head of the Department of Mechatronics Engineering

Dr. Ram Dayal

Sarthak Saxena
 ABSTRACT

Every Industry or even most houses have electrical control panels in them in one type or
the other. These control panels control the electrical circuitry of any machine or building and are
of utmost importance to any organization whatever its field of working may be.

With the wide spread need there arises a wide variety of control panels that could exists with
different components, different design philosophy and needs altogether. Here we will be
studying the variety of basic building blocks, various design philosophies and different
fabrication techniques involved with electrical control panel.

In this project, an attempt has been made to quantify and simplify the process of control
panel design and fabrication by introducing newer manufacturing and designing tools available
at hand.
 CONTENTS

TITLE Page no.

List of Abbreviations i
List of Figures ii

1. Introduction------------------------------------------------------------------------------------------ 1

2. Guidelines from NEC------------------------------------------------------------------------------ 2

2.1 Typing, sizing, and siting---------------------------------------------------------------- 2

2.2 Supply conductors------------------------------------------------------------------------ 3
2.3 Overcurrent protection------------------------------------------------------------------- 4
2.4 Short circuit current rating--------------------------------------------------------------- 4
2.5 Grounding---------------------------------------------------------------------------------- 5
2.6 Workmanship------------------------------------------------------------------------------ 5
2.7 Maintenance------------------------------------------------------------------------------- 6
2.8 Pest control-------------------------------------------------------------------------------- 6
2.9 Dust control-------------------------------------------------------------------------------- 6
2.10 Connection control------------------------------------------------------------------------6
2.11 Insulation---------------------------------------------------------------------------------- 7

3. Components----------------------------------------------------------------------------------------- 8

3.1 Enclosure--------------------------------------------------------------------------------------- 9
3.2 DIN Rails------------------------------------------------------------------------------------ 10
 3.3 Human interaction I/O--------------------------------------------------------------------- 13
3.4 Misc. components acc. to the objective------------------------------------------------- 14

3.4.1 CABLES------------------------------------------------------------------------ 14
3.4.2 BUS BAR----------------------------------------------------------------------- 14
3.4.3 MCB (Miniature Circuit Breakers) ----------------------------------------- 15
3.4.4 MCCB (Mold Case Circuit Breaker) --------------------------------------- 15
3.4.5 ELCB (Earth Leakage Circuit Breaker) ------------------------------------16
3.4.6 INCOMER--------------------------------------------------------------------- 16
3.4.7 SELECTOR SWITCH-------------------------------------------------------- 16
3.4.8 Starters-------------------------------------------------------------------------- 17
3.4.9 OVER LOAD RELAY------------------------------------------------------- 17
3.4.10 TIMER-------------------------------------------------------------------------- 18
3.4.11 CONTACTOR----------------------------------------------------------------- 18

4. Cooling-------------------------------------------------------------------------------------------- 19

4.1 What is Air Conditioning? --------------------------------------------------------------- 19

5. Ferrules and Cable labelling------------------------------------------------------------------- 22

5.1 Cable Identification Tags------------------------------------------------------------------ 22

5.2 Wire Markers------------------------------------------------------------------------------- 22
5.3 Heat Shrink Labels------------------------------------------------------------------------- 23
5.4 Pipe Markers-------------------------------------------------------------------------------- 23

6. Design--------------------------------------------------------------------------------------------- 24

6.1 Conventional Design----------------------------------------------------------------------- 25

6.2 Modern CAD based designing------------------------------------------------------------ 26
 7. Fabrication---------------------------------------------------------------------------------------- 28

7.1 Labor Intensive---------------------------------------------------------------------------- 29

7.2 Machine Intensive-------------------------------------------------------------------------- 30

REFERENCES-------------------------------------------------------------------------------------------- 31
BIBLIOGRAPHY---------------------------------------------------------------------------------------- 32
 i

List of Abbreviations

NEC National Electrical Code

DIN Deutsches Institut fr Normung

 ii

List of Figures

Figure No. Title Page No.

1 Enclosure 9
2 Top hat 10
3 C section 11
4 G section 12
5 Panel mount I\O 13
6 HMI 13
7 Cable 14
8 Bus Bar 14
9 MCB 15
10 MCCB 15
11 ELCB 16
12 Incomer 16
13 Selector switch 17
14 Starter 17
15 Overload Relay 18
16 Timer 18
17 Figure 1 19
18 Flowchart 21
 CHAPTER 1
INTRODUCTION

What is an Electrical Control Panel?

A control panel is a flat, often vertical, area where control or monitoring instruments are
displayed or it is an enclosed unit that is the part of a system that users can access, as the control
panel of a security system (also called control unit).

They are found in factories to monitor and control machines or production lines and in places
such as nuclear power plants, ships, and aircraft and mainframe computers. Older control panels
are most often equipped with push buttons and analog instruments, whereas nowadays in many
cases touchscreens are used for monitoring and control purposes.

NEC

For NEC purposes, an industrial control panel operates at less than 600V and consists of power
circuits and/or control circuits. A control circuit provides the signals directing the performance of
the controlled equipment but doesn't carry the main power or include the controlled equipment.
The panel part means the control system is mounted on (or in) an enclosure or subpanel
[409.2].

The NEC allows you to use the control panel as a junction box for other wiring or systems
[409.104(A)], if you provide ample space for this purpose. However, such a design sacrifices
modularity, complicating maintenance and making inductive noise and other problems more
likely. Double duty seldom saves much money up-front and may create huge costs later.

1
2. Guidelines from NEC

Article 409 provides the minimum safety requirements for industrial control panels (What's an
Industrial Control Panel? below). Because this section of the Code is only a couple of pages
long, it isn't that comprehensive. However, Table 409.3 lists more than two dozen other Articles
that may apply to a given control panel, which definitely broadens its scope.

The NEC is primarily concerned with the hazards arising from the use of electricity, not the
myriad of other issues that arise with industrial control panels. Thus, some things allowed by Art.
409 aren't optimal (What Purpose Does it Serve?). When there's a controls malfunction, the
cause is unlikely to be an Art. 409 violation, unless the problem is of the where's that smoke
coming from? variety.

Standards other than the NEC also apply to industrial control panels. Two that always apply are
UL 508A, Standard for Industrial Control Panels, and NFPA 79, Electrical Standard for
Industrial Machinery. NECA, NETA, and IEEE also have produced applicable standards for
design, installation, testing, and/or maintenance. One more reference is critical. When industrial
controls exhibit intermittent operation, a common cause is non-compliance with Art. 250 Part V
(bonding). So make sure to build that compliance into your design and installation specs. Let's
take a look at some specific guidelines.

2.1 Typing, sizing, and siting

Select the type of enclosure based on the intended environment. To determine the enclosure size,
rough out its back planes, termination strips, and major component locations. Allow for enough
space to install and wire these items with proper routing and bend radii.

An overlooked issue with larger control panels is the need to power test equipment and
appliances, such as vacuums used for maintenance. Rather than ensure the need for extension

2
cords, add sufficient receptacles at convenient locations, and allow for these in your rough
layout. But don't place the order just yet. Work with your electrical distributor to see what
standard offerings are closest to what you need. This collaboration can produce significant
savings in cost and delivery.

If your panel is moderately complex, then you may have the option of supplier engineering.
Don't try to save money by not purchasing this. Have the supplier engineer the panel once rather
than redoing it in the field while under pressure from management to get this thing going.

Once you have the panel designed, you must figure out where to put it. Determine the outside
dimensions and the swing requirements of cabinet doors. To reduce maintenance inefficiencies
and other hidden costs during operation, allow enough room for a test cart to roll across the area
with those doors open.

Control panels often are near the process area. A high ambient temperature may require a
ventilation fan or even air conditioning on the cabinet, both of which will have filters that require
maintenance. Other circumstances may dictate adding a heater or dehumidifier. Locate the air
intakes and exhaust vents for easy filter replacement and ensure there is no process interference;
having a cabinet vent suck in air off an aluminum melting pot is generally not helpful. [4]

2.2 Supply conductors

Figuring out the ampacity for the supply conductors can be confusing unless you break down the
requirements into the following discrete steps:

Calculate the full load current (FLC) rating of all resistive loads.
Add to this 125% of the FLC of the highest rated motor.
Add to this the sum of the FLC of all other connected motors and apparatus, based on their duty
cycles and based on what will be operating simultaneously.
On the third step, the process might make the operation of various apparatus mutually exclusive
for any number of reasons (e.g., Operation A must occur before Operation B). Allow for the

3
highest load that would occur.

2.3 Overcurrent protection

You can either put overcurrent protection ahead of the panel or put a single main overcurrent
protective device (OCPD) in the panel [409.21]. Which way is better? The answer depends on
many factors. One reason not to locate OCPDs in the panel is that you want to minimize the
opening of the panel because of the process environment. Don't confuse OCPD functionality
with disconnect functionality. You don't have to co-locate these. For the disconnect, just apply
the requirements of Part IX of Art. 430.

The rating of the OCPD for the panel must not be greater than the sum of:

125% of the FLC of all resistance heating loads.

The sum of the FLCs of all other equipment that could be in operation at the same time.
The largest rating (or setting) of the branch circuit and ground-fault protective device provided
with the panel.
If the panel doesn't come with a branch circuit and ground-fault protective device, use 430.52
and 430.53 as applicable.

2.4 Short circuit current rating

The NEC requires marking every panel with its short circuit current rating (SCCR) [409.110)].
Listed components and assemblies have the SCCR marked on them. Unless you're buying a
listed control panel assembly and that's unlikely you must determine the SCCR of the
panel and mark it accordingly. But how?

UL 508A contains an example of an approved method of SCCR determination [409.110 FPN],

but you can use a simpler method. The SCCR is really the withstand rating of the device or
assembly [110.10]. This means that, like the weakest link in the chain, the device with the lowest

4
rating limits the entire assembly to that rating. The control panel SCCR is the SCCR of the
lowest-rated device in the enclosure. Caution: Make sure the SCCR is adequate for the available
fault current.

2.5 Grounding

Don't ground this panel. Although its title is grounding, Sec. 409.60 provides the requirements
for bonding (see Art. 100 definitions). Make sure there's no difference of potential between
enclosure parts and any nearby metallic objects. Install an equipment grounding (bonding)
conductor or grounding (bonding) bus sized per Table 250.122.

If the panel is part of a manufactured system, the manufacturer may require an isolated ground
as a condition of warranty. The intended meaning of this often isn't the same as that defined by
the NEC or IEEE-142. If the manufacturer requires driving an isolated ground rod, that's an
unenforceable condition of warranty because of its underlying illegality. Nobody can require a
code violation as a condition of warranty. This isolated ground rod idea is based on the
misperception that electricity seeks the path of least resistance, instead of being subject to
Kirchhoffs Law of Parallel Circuits. In fact, such an installation ensures the very failures it
allegedly prevents. Follow accepted engineering practices, not arbitrary requirements based on
voodoo physics. See Art. 250, Part V for how those practices apply to equipment bonding.

2.6 Workmanship

In a cabinet installed with good workmanship, the wires are neatly bundled, run in gutters or
similar supports, and routed with smooth radius bends and all terminals, wires, and
components have identification labels.

A good labeling strategy saves time and reduces errors in terminating, testing, maintenance, and
repair. Don't use handwritten labels. You can choose from many available labeling solutions to
produce legible, durable labels in an efficient, cost-effective manner.

5
To the extent possible, run power, control, and signal wiring in separate bundles/gutters, even if
that means using more wire. This will improve noise immunity, reduce troubleshooting time, and
make future changes easier.

2.7 Maintenance

Article 409 doesn't address control panel maintenance, but common sense says a small amount of
maintenance provides huge gains in reliability. Some basic things that need to be in the
preventive maintenance procedures include:

2.8 Pest control

This may consist of a rodent trap in one corner. Whatever method, ensure it's inspected
periodically.

2.9 Dust control

Vacuum the accumulated dust off the cabinet floors. If conditions require vacuuming anything
else, remember it's an energized cabinet follow the applicable procedures. Don't vacuum near
circuit boards without following electrostatic discharge (ESD) rules.

2.10 Connection control

It seems counterintuitive, but re-tightening terminal screws causes loose connections. Instead of
inadvertently over-tightening terminal screws (consequently diminishing their clamping power),
use an infrared gun to see which terminals are high resistance. Disassemble, clean, and
reassemble.

6
2.11 Insulation

An insulation resistance testing program is the best way to prevent wiring failures.
By taking a few extra steps in the selection, design, and installation of an industrial control panel,
you can ensure it will have no failure time bombs ticking away. With a modest maintenance
program, it will be nearly problem-free for its entire life.

7
 3. Components
8
3.1 Enclosure

An electrical enclosure is a cabinet for electrical or electronic equipment to mount switches,

knobs and displays and to prevent electrical shock to equipment users and protect the contents
from the environment. The enclosure is the only part of the equipment which is seen by users; in
many cases it is designed not only for its utilitarian requirements, but also to be pleasing to the
eye. Regulations may dictate the features and performance of enclosures for electrical equipment
in hazardous areas, such as petrochemical plants or coal mines. Electronic packaging may place
many demands on an enclosure for heat dissipation, radio frequency interference and
electrostatic discharge protection, as well as functional, esthetic and commercial constraints.

Electrical enclosures are usually made from rigid plastics, metals, particularly stainless steel,
carbon steel, and aluminum. Steel cabinets may be painted or galvanized. Mass-produced
equipment will generally have a customized enclosure, but standardized enclosures are made for
custom-built or small production runs of equipment.

-img.weiku.com

9
3.2 DIN Rails

A DIN rail is a metal rail of a standard type widely used for mounting circuit breakers and
industrial control equipment inside equipment racks. These products are typically made from
cold rolled carbon steel sheet with a zinc-plated or chromated bright surface finish. The term
derives from the original specifications published by Deutsches Institut fr Normung (DIN) in
Germany, which have since been adopted as European (EN) and international (IEC)
standards.[1]

Types

There are three major types of DIN rail:[2]

Top hat section, type O, or type , with hat-shaped cross section.
C section
G section

Top hat rail EN 50022

This 35-mm wide rail is widely used to mount circuit breakers. The EN 50022 standard
specifies both a 7.5 mm (shown above) and a 15 mm deep version, which are officially
designated

top hat rail EN 50022 35 7.5

top hat rail EN 50022 35 15

10
Some manufacturers catalogs also use the terms Top hat section / Type O / Type
Omega ().

It is known as the TS35 rail in the USA.

C section
These rails are symmetrical within the tolerances given. There are four popular C
section rails, C20, C30, C40 and C50. The number suffix corresponds to the overall
vertical length of the rail.

G section

G-type rail (according to EN 50035, BS 5825, DIN 46277-1).

11
Others
In addition to the popular 35 mm 7.5 mm top-hat rail (EN 50022, BS 5584, DIN 46277-
3), several less widely used types of mounting rails have also been standardized:
Miniature top-hat rail, 15 mm 5.5 mm (EN 50045, BS 6273, DIN 46277-2);
75 mm wide top-hat rail (EN 50023, BS 5585);

12
3.3 Human interaction I/O

For the human interaction with the control panel to give commands and set the parameters on the
panel we can use a host of devices like different type of push buttons and HMIs. We also deploy
LED indicators, meters etc. on the panel itself to display the current conditions of the quantified
parameter [9]. Some of the devices are shown in the figure below. [5]

-
mall.industry.siemens.com/collaterals/
files/46/JPG/P_ST80_XX_02156j.JPG

-image.made-in-
china.com/44f3j00aTytoCLUIvpu/30mm-
16mm-Panel-Mount-Indicator-Light-Lever-
Switch-Push-Button.jpg

13
3.4 Misc. components acc. to the objective [6]

3.4.1 CABLES
Cables are used for the interconnection. Two types of cables are used. Power cable and control
cable.
1. Power cables (which is used to connect the motor to panel component and panel to main
supply)
2. Control cables (which is used to connect the control circuits) [10]

3.4.2 BUS BAR

Incoming supply is connected to bus bar and distributed from bus bar. It is normally made by
Aluminium.

14
3.4.3 MCB (Miniature Circuit Breakers)

MCB is a protecting device. It is used before the feeder. This should be selected according to the
capacity of the feeder

3.4.4 MCCB (Mould Case Circuit Breaker)

In most of the cases the MCCB used as an incomer for higher capacity feeders for better
protection

15
3.4.5 ELCB (Earth Leakage Circuit Breaker)
The ELCB is also known as RCCB. The device used for the protection against the earth leakage
current and residual current. It should be fixed before the incomer

3.4.6 INCOMER
The basic supply will connected to this incomer. It also called as SFU(Switch Fuse Unit). It
contains one handle with fuse unit. Once it is turned ON the supply will pass to the next stage
through fuse if any major fault occurs in side panel board, it will trip and it isolate supply.

3.4.7 SELECTOR SWITCH

Selector is switch is used for ON/OFF purpose and for selecting the mode of operation like
auto/manual.

16
3.4.8 Starters

Starters are used for starting the motors safely. Mainly two types of starters are there. DOL
starters and Start to delta. Dol starter is enough for the motors with power less than 10 hp.

3.4.9 OVER LOAD RELAY

Over load relay is for the protection of motor from the over load. It senses the load current and
trips if it exceeds the limit. Current limit has to be set manually. It should be 80% of the full load
current.

17
3.4.10 TIMER

Operation of timer is similar to relay. But a delay is there for actuation. We can set the time
delay manually according to our requirement. It is very much essential for start to delta
conversion.

3.4.11 CONTACTOR

Contactor is an essential component in the control panel. It actuates when the signal from the
controller (PLC, Relay logic) comes. It is similar to relay. It is costlier than relay. It is used for a
higher load.

18
4. Cooling

4.1 What is Air Conditioning?

Air conditioning by definition is a means to cool and remove humidity from an environment,
such as an enclosure, through use of a refrigerant cooling cycle. Air conditioners currently are
the only practical stand-alone device in the market that can cool an environment below ambient
temperatures. There are other devices in the marketplace that can cool below ambient (e.g. air to
water heat exchangers), but these devices require a secondary coolant source supply to the unit,
such as a chiller. [7]
The impact of increasing temperatures
As technology in electronic packaging has advanced, so has the impact of thermal loading and
temperature rise to these electronics. Smaller electronic components and increasingly dense
packaging in enclosures have made these systems much more sensitive to external influences
such as temperature, dust, oil and humidity.
This can be problematic because the failure of just one electronic component may lead to the
complete shutdown of an entire production line. Resulting costs add up quickly.
Heat is the number one enemy of electrical and electronic equipment!

Looking at Figure 1, you will see that 57% of all component failures are heat related, followed
by vibration, humidity and dust respectively. The use of air conditioners can help you eliminate
three of these potential system failures. (Temperature,
Humidity, and Dust) As a rule of thumb it is said that the average life span of semi-conductors is

19
reduced by 50% every time the operating temperature rises 20F (10C) over its maximum
operating temperature. Yet, high temperatures in enclosures can hardly be avoided because
electronic equipment such as transformers, power distribution components, drives, PLCs and
PCs all generate heat ~ known as heat loss. [8]

20
21
5. Ferrules and Cable labelling

Color-coding of cables is sometimes used to keep track of which is which. For instance, the
wires coming out of ATX power supplies are color-coded by voltage.[1] Documenting and
labeling cable runs, tying related cables together by cable ties, cable lacing, rubber bands or other
means, running them through cable guides, and clipping or stapling them to walls are other
common methods of keeping them organized. Above drop ceilings, hooks or trays are used to
organize cables and protect them from electrical interference

Planning is especially crucial for cables such as Thicknet that do not bend around corners easily
and fibre optic which is very difficult to splice once cut. [12]

5.1 Cable Identification Tags

A cable ID tag typically consists of a tie that loops around cables (or cable bundles) with a tag on
the end that serves to identify what it's wrapped around. There are many pre-printed varieties, or
blank options such as Kableflags that let you write in whatever type of label you wish. These
tags are useful because they allow for an easily readable, highly visible flat surface to clearly
show the ID. On the other hand, a possible drawback is that in tight spaces, a tag that hangs off
of cabling or bundles can take up room and be cumbersome. There are several varieties of tags,
some with hook and loop closures, and others like Unitags that can be rotated 360 degrees for
even more convenient identification. Tags are found just about everywhere, from the networking
and electrical fields to home use in entertainments systems and home theatres. [13]

5.2 Wire Markers

Wire markers typically wrap around the cable and feature an identifying mark, usually a number
or a colour, so you can easily ID a cable at a glance. By using numbers and/or colours, the
labelling process is simplified, as it can be difficult to read longer text around the surface of a
thin wire. A wire marker might be a tape that uses adhesive to wrap around the individual cable,
or it may be a plastic expandable ring that clips around the circumference. Wire markers are used

22
to ID a single cable, and aren't large enough to accommodate bundles.

5.3 Heat Shrink Labels

If you need a wrap-around label in an environment where an adhesive label with the potential to
peel is absolutely not an option, a heat shrink label may be your best bet. These labels are sleeves
that fit around cables, then shrink to conform to the size and shape of the cable via application of
heat. This creates a snugly fit label around wires and cables that won't peel or slip off, and can be
used in a wide variety of environmental conditions. There are military grade heat shrink labels
designed for radiation exposure, thermal aging, and more. So, for an application that needs to be
long-lasting and stand up to tough environmental conditions, heat shrink may be preferable to
typical adhesive wire markers.

5.4 Pipe Markers

Much like identifying cables, it's important to properly mark pipes to ensure that things like
contents, flow direction and more are evident and visible. There are a few different types of
markers to identify pipes, including fastening systems that strap, snap or mount a label on the
pipe, or adhesive markers that stick directly to pipes. A mounting clip straps onto the pipe and
keeps your label separate and away from the pipe, in case the contents within or the pipe surface
could affect the label. A strap-on system attaches the marker without using adhesives, so that it
can be secured to a textured or oily surface. For simpler applications, adhesive pipe markers or
banding tape may suffice.

23
 6. Design

24
6.1 Conventional Design

Conventional method of design is to have a skilled electrician draw up the plans for the panel
according to his knowledge of the subject as required by the task at hand. This would lead to
longer and inefficient design process with windows for errors.

25
6.2 Modern CAD based designing

There are now a host of different software available to ease and simplify the designing process
involved. Designers and engineers can quickly define the electrical interconnect of complex
electrical systems with our easy-to-use electrical system design solutions in SOLIDWORKS
Electrical. Utilizing intelligent single line or traditional multiline schematics, and a library of
thousands of electrical schematic symbols and parts, you develop embedded electrical system
designs in a real-time, collaborative multi-user environment that connects mechanical and
electrical engineering. [11]

Few Solutions [3]

Electrical Schematic Creation

SOLIDWORKS Electrical Schematic provides a standalone, easy-to-use, electrical design

system to efficiently define electrical interconnections for complex electrical systems

Electrical Design in 3D CAD

It provides easy-to-use CAD-embedded, electrical system design to integrate electrical schematic

design data from Electrical into a 3D CAD model.

Embedded Electrical System Design Planning

It provides a powerful, easy-to-use planning tool for rapid design of schematically defined
embedded electrical systems in the 3D CAD model.

Collaborative Electrical-Mechanical Development

26
Multiple electrical and mechanical engineers can work on the same project simultaneously.

Electrical Harness Design Planning

It can create a virtual design in-place electrical harness development environment.

3D Electrical Cabinet Design

Combining CAD and Electrical technologies, it can provide a design environment enhanced for
electrical 3D cabinet design. Through the use of easy-to-use, industry-proven automation tools, it
provides superior capability and usability for all aspects of electrical 3D cabinet design and
documentation.

Mechatronic Design

It provides a powerful, easy-to-use solution to integrate electronics into electro-mechanical

designs. Through seamless integration of Circuit Works, it provides a comprehensive solution
for schematically driven embedded electronics, and detailed electrical interconnect seamlessly
into mechanical design, within a perfect environment for complex mechatronic design.

Schematic Annotation and Documentation

It provides a powerful, easy-to-use annotation, documentation, and reporting solution that
incorporates the power and ease of DraftSight, seamlessly integrated into the Electrical
collaborative design environment, to provide real-time annotation, documentation, and reporting
for Electrical projects.

27
 7. Fabrication
28
7.1 Labor Intensive
The most general way to fabricate an Electrical control panel is by taking the use of manual labor
to read plan and fabricate the panel by hand. Here, a semi-trained personnel or a group of
personals do all the work from reading the requirements, Gather the parts required and assemble
the panel as required and test it as well.

Advantages

Cheap
Minimal initial investment
Highly trained workforce not required

Disadvantages

Extremely slow
Quality not in par with automated solutions
Window for human error
Reduces redundancy

29
7.2 Machine Intensive
With the onslaught of automation services there is a whole load of new machines coming in to
ease the work of building an electrical panel. Auto drillers to drill and tap holes on the panel
base, wire strippers and crimpers to cut the wire to length strip it and crimp a lug on it, wire
labelers to label the wires according to the circuit diagram and machines like Athenos to
assemble the whole panel on its own are few of the examples of modern fabrication technologies
available to ease the work.

Advantages

Prefect quality
Fast
Repeatability
More efficient
Mainly unskilled labor needed to operate the machines

Disadvantages

High initial cost

Maintenance cost high
Need skilled worker to repair and maintain the Equipments

30
REFERENCES

1. Simpson, Robert (2003). Lighting Control: Technology and Applications. Oxford

UK: Focal Press/Elsevier. ISBN 0-240-51566-8.
2. Jump up^ Tickoo, Sham (2010). AutoCAD Electrical 2010 for Engineers. India:
Dorling Kindersley. pp. 846. ISBN 978-81-317-3213-7.
3. http://www.solidworks.in/sw/products/electrical-design/solutions.htm
4. Smith, Robert L. (2004). Electrical Wiring Industrial: Based on the 2005 National
Electric Code. Delmar. p. 52. ISBN 978-1401851545
5. Pigan, Raimond (2008). Automating with PROFINET: Industrial communication
based on Industrial Ethernet. Publicis Publishing. p. 389. ISBN 978-3-89578-294-7.
6. https://www.cableorganizer.com/cable-identification/
7. K. Beckert ; H. Herwig. Inclined air to air heat exchangers with heat pipes:
comparing experimental data with theoretical results Print ISSN: 1089-3547
8. J.R. McKay Use of an air-to-air heat exchanger to reduce peak temperatures in
outdoor cabinets Publisher: IEEE
9. Wenke Kang ; Changde Lu ; Xiaojie Gao ; Minjiu Yu Research on the industrial
design method of control panel based on man-machine engineering restriction
Print ISBN: 978-1-4244-3290-5
10. Ruzlin M. M. Mohd ; Shafi A. H. Huzainie ; Basri A. G. Ahmad Study of cable
crimping factors affecting contact resistance of medium voltage cable ferrule and
lug Electronic ISBN: 978-1-84919-732-8
11. Alexander S. Nikitin ; Fedor G. Zograf ; Alexander M. Fen ; Sergey I. Tregubov
Specials of electrical wiring in Altium Designer & SolidWorks Electronic ISBN:
978-1-4799-1062-5
12. J.M. Bene Design of electrical process/control panels-the missing standard
Publisher: IEEE
13. Jana Reisslein ; Amy M. Johnson ; Martin Reisslein Color Coding of Circuit
Quantities in Introductory Circuit Analysis Instruction Print ISSN: 0018-935

31
BIBLIOGRAPHY

www.google.com
www.wikipedia.com
www.rittal.com
www.seimens.com
www.solidworks.in
NEC
DIN regulations
IEC regulations

32