Industry 4.0 Manufacturing

The new 250 million-euro Rittal plant in Haiger embraces the principles of Industry 4.0.

It represents the company’s largest-ever single investment, enabling them to establish the world’s most advanced manufacturing facility for its new compact and small enclosures.

The plant’s highly automated production processes – working in conjunction with the neighbouring distribution centre (GDC) – enable seamless order fulfilment, guaranteeing ongoing availability of standard products and accessories.

Rittal is putting Industry 4.0 theory into practice. 

The world’s leading provider of solutions for enclosures, power distribution, climate control and IT infrastructure (as well as corresponding software and services) is creating a smart factory which will become the world’s most advanced production plant for compact and small enclosures.

“The plant will be fully aligned with highly efficient Industry 4.0 principles,” states Professor Friedhelm Loh, Owner and CEO of the Friedhelm Loh Group.

“The new manufacturing site will also safeguard future competitiveness for our customers and our own business. The total investment of 250 million euros is a positive statement in terms of the regional economy and the 290 jobs at our Haiger plant. We have quite consciously decided to proactively shape the future with the local people who made us what we are today.”

The new factory halls cover 24,000 square metres of floor space and will soon house more than 100 high-tech machines.

Around 9,000 AX compact and KX small enclosures will be manufactured every day, processing approximately 35,000 metric tons of steel annually.

Manufacturing in a smart factory

The equipment will be highly automated, producing individual items which are then assembled with exceptional efficiency.

In the past, individual steps such as cutting to size, edging, welding and painting were transactional, sequential and independent of one another. In the new era, all workers, machines and materials will be increasingly integrated into the manufacturing execution system.

At the end of the process, the individual assemblies are automatically merged and a QR code is applied, for easy identification and onward processing by the customer.

Both the machines and handling systems communicate with each other and with higher-level control systems via modern industry 4.0-capable communication networks.

Materials and components will be moved using 20 automated, guided vehicles. Packaging, marking and transfer to the distribution centre are managed automatically. Knowledge-based “learning” systems will enable predictive maintenance, preventing faults from occurring and minimising downtime.

Automated order management and fulfilment will guarantee the ongoing availability of standard products and accessories in the nearby global distribution centre, creating an end-to-end digital process chain – from configuration and engineering on the part of the customer, to shipment of the end-product.

A new world of work in Haiger

The new era of industrial manufacturing will also usher in major changes for the associated manpower.

There will be fewer strenuous manual tasks, such as lifting and carrying; instead, the focus will shift to controlling, monitoring and fine-tuning processes.

“The expertise and capabilities of experienced employees are one of the keys to the success of smart factories: systems can only learn and gain intelligence if they are taught systematically by humans,” explains Professor Loh.

Rittal proactively develops the digital skills of its workforce through training courses held at the Loh Academy.

The new technologies will bring improvements to the working environment as a whole. The Haiger facility will be quiet, clean and energy-efficient. For example, waste heat from the new paint shop will be recovered and reused, e.g. for degreasing components or for heating the factory halls. Efficient use of water is also a high priority. Process water is managed within a closed-loop system, where it is cleaned and reused.

Digital value creation at the customer organisation

Rittal will be manufacturing its new AX compact and KX small enclosures at the new plant.

Digital transformation has created new challenges in terms of the products themselves, the operating environment, and its availability. Rittal has therefore rethought and redesigned this offering inline with the imperatives of Industry 4.0.

Rittal provides effective support for the entire value chain for the production of panels and switchgear, from engineering to ordering to automation. Its digital product twin delivers high-quality data for the entire design, configuration and manufacturing process. This approach for the new AX and KX range echoes the successful launches of the Blue e+ cooling units and VX25 large baying enclosures.

Digital transformation is vital to business success

The Haiger facility is a pilot for the real-world implementation of Industry 4.0 and will act as a role model for Rittal’s international operations.

It will also be a pioneer and reference for Rittal’s own products and services in terms of the Industrial Internet of Things (IIoT).

Blue e+ cooling units further increase energy efficiency and are integrated into the monitoring and energy management systems via the IIoT interface. The entire machine park permanently provides data from the control system and the current operating states.

Production systems in the new factory deliver an ongoing source of actionable data on their operational status. In future, this information will be collected by an on-site edge data centre and analysed using powerful applications developed by sister company Innovo.

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Rittal EC fan-and-filter units with speed control

Rittal fan-and-filter units with EC (electronically commutated) motors should be the preferred choice for energy efficiency in enclosure climate control, as their operating ratio is significantly higher than standard AC fan-and-filter units.

Using fan-and-filter units always makes sense if the difference between the outdoor temperature and the internal enclosure temperature is large enough to dissipate the thermal output of the installed components. However, the fans mostly operate without regulation. In other words, they run constantly and always at full speed. In this situation, the savings potential offered by seasonal temperature fluctuations or temperature reductions in the building (e.g. on night shifts or through reduced waste heat in the enclosure) remains unused.

Further optimisation potential exists with an advanced solution using Rittal fan-and-filter units with temperature-dependent speed control. With a new sensor for controlling the speed of the Rittal EC fan-and-filter units, inherently up to 30% more efficient than comparable AC fan-and-filter units, power consumption can be drastically reduced yet again. The sensor measures the temperature within the enclosure and controls the fan speed as needed, right up to independent shutdown at below 20°C.

Replacing AC systems without speed control by EC systems with system control saves money, as shown in the following example: At a manufacturing plant with 50 fan-and-filter units (700 m³/h), run at full load for two shifts per day and five days a week, needing only 20% of the fan speed at night and weekends with reduced enclosure temperatures (20°C), EC technology and intelligent controls, can more than halve the energy costs.

Read more at http://www.rittal.com/uk-en/content/en/unternehmen/presse/pressemeldungen/pressemeldung_detail_32832.jsp

Rittal TopTherm EC fan-and-filter units

Rittal TopTherm EC fan-and-filter units

 

Rittal Enclosures, Power Distribution, Climate Control, IT Infrastructure, 19 inch Racks, Software & Service – http://www.rittal.co.uk

Rittal’s new operating housings

Rittal’s new operating housings based on AE with handle strips, unveiled at this year’s Hanover Fair, have been noted for their attractive eye-catching design, based on the support arm system system CP 60/120/180.

Supplied as standard, the new operating housings with handle strips benefit from a standardised design and operation and replace the existing range of sheet steel operating housings.

Encompassing many new and enhanced features, such as rear or front access for servicing, an aluminium front panel easily dismantled for machining, lock with integral door runners for easy locking and uniform interior installation via Rittal system accessories.

Available in 10 standard sizes, ex-stock, with protection category IP55, Rittal’s new housings are elegantly fabricated, with high functionality which will stand out thanks to the modern, attractive design, one-man assembly and support arm connection.

Read more at http://www.rittal.com/uk-en/content/en/unternehmen/presse/pressemeldungen/pressemeldung_detail_31872.jsp

Rittal New operating housings  fri131307610

 

 

Rittal Enclosures, Power Distribution, Climate Control, IT Infrastructure, 19″ Racks, Software & Service – http://www.rittal.co.uk

Safe and simple locks

Rittal’s new TS 8 isolator door cover, when deployed in tandem with the actuation mechanisms, adjacent door locking and interconnecting rods, fulfils all requirements of the UL 508 A standard. (A requirement for the North American market.)

Featuring a raft of technical updates and design features, Rittal’s TS 8 isolator door cover range, prevents operators from opening the enclosure and touching live electrical components. The isolator door cover is mounted on the side of the enclosure to which an actuator lever or isolator switch, as the master switch, can be integrated. As a result, the door can only be opened when the isolator switch has been activated and the electricity supply to all components in the enclosure has been disconnected.

A complete row of bayed enclosures can be made safe using a single isolator door cover. The door of the neighbouring enclosure is then operated via the adjacent door latch.
Easy to assemble, the 125-mm-wide isolator door cover can be mounted on either the left or right of the enclosure by a single person. The revised locking mechanism consists of a small number of compact parts, is easy to assemble and can be deployed for all approved actuator levers. Standard side panels can be fitted on the side opening of the isolator door cover with automatic potential equalisation.

 

http://www.rittal.com/uk-en/content/en/unternehmen/presse/pressemeldungen/pressemeldung_detail_31808.jsp

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Rittal Enclosures, Power Distribution, Climate Control, IT Infrastructure, 19″ Racks, Software & Service – http://www.rittal.co.uk

Efficient cooling from Rittal

Germany manufacturer SHW Werkzeugmaschinen GmbH, from the Swabian, manufacture moving column machine tools. Machinery from the company includes a 200-ton moving column milling machine, the PowerForce 8, which is used to mill wind turbine stators with an internal diameter of 6.5 m. At the heart of the mill is a new, variable, universal milling head of orthogonal design with a drive power of 90 kW and a torque of up to 1,725 Nm.

SHW relies on the new “Blue e” generation of cooling devices from Rittal to exploit every possible efficiency potential in enclosure climate control. Consuming 45 per cent less energy than the previous generation, the four wall-mounted devices installed on the machine provide cooling of the input and feedback modules for the axle drive, mains filters, chokes, disconnectors, contactors, relays and have a cooling output amounting to 16 kW. The refrigeration factor of 2.47 (the COP, coefficient of performance) results from the ideal interaction of all the components responsible for the cooling output, as well as from the design of the condensers, evaporators, cooling fins, pipe bends and all the other refrigeration components. Using Rittal cooling technology, SHW have been able to connect the devices via a master-slave arrangement.

Another key factor in the increased efficiency is the ideally designed control electronics, which benefit from the new Eco-Mode control system. If continuous operation of the internal fan is not required, shut down is automatic, thus cutting energy costs.

Previously SHW had problems with cooling devices from another manufacturer that malfunctioned under extreme conditions, due to the influence of carbon dust. Since changing to ex-proof cooling units from Rittal, they have been running without problems.

 

For more info and News from Rittal : http://www.rittal.com/uk-en/content/en/unternehmen/presse/pressemeldungen/pressemeldungen.jsp

Blue e Wall-Mounted Cooling Unit-s

Rittal Enclosures, Power Distribution, Climate Control, IT Infrastructure, Software & Service – http://www.rittal.co.uk

Rittal cooling solution boosts data-centre energy efficiency

Rittal’s new Liquid Cooling Package (LCP) Hybrid, with a cooling capacity of up to 20kW per rack, comprises a large, high-performance air/water heat exchanger that cools IT components installed inside the server enclosure.

Delivering an energy-efficient IT cooling solution, the LCP Hybrid, with a thermal output of up to 10 kW, is especially suitable for data centres and up to 20 kW for IT racks used in university and auto-industry super-computers. Rittal’s LCP Hybrid does not require a dedicated fan or additional electricity for cooling as the fans integrated into the server direct warm air to the heat exchanger via baffle plates.

One of the key innovations is an integrated heat pipe that ensures the entire cooling surface is used to best effect. Air cooled by the heat exchanger is returned to the data centre, ensuring that all racks are cooled reliably. Intake air does not need to be extremely cold, so indirect free cooling can be used for the majority of the year. Chillers are only activated if high ambient temperatures prevent water from being cooled adequately.

Rittal has moved the water connection hoses directly onto to the rear door frame, requiring less material and taking up no additional space when the rear door is opened. This saves a great deal of time and effort when planning the piping system. The rear-door solution delivers outstanding energy efficiency, saves space and is easy to install.

Available in four sizes for each of two cooling output categories, 10 kW and 20 kW, the LCP Hybrid can be deployed for IT racks up to a height of 2,200 mm, is tailored to the needs of the Rittal TS IT rack system for server and network technology and builds upon the success of the LCP Passive.

For more info: http://www.rittal.com/uk-en/content/en/unternehmen/presse/pressemeldungen/pressemeldung_detail_31680.jsp

 

Rittal's (LCP) Hybrid pipe

 

 

Rittal Enclosures, Power Distribution, Climate Control, IT Infrastructure, Software & Service – http://www.rittal.co.uk

Rittal’s cost-efficient SE 8 Enclosures

Efficiency is a top priority in panel building and switchgear design and savings can be made by increasing productivity. Using an engineering solution to draw up electrical plans and documentation, in an essentially automated process, customers can benefit from a fully integrated data workflow.
There is also a need for enclosures that are based on a uniform system platform to suit various applications. It is advantageous when switchgear projects (across all industry sectors with very different requirements) can be implemented with one single enclosure system platform.
Rittal has “docked” their SE 8 enclosure system to its’ existing TS 8 platform, which now offers the same configuration options as traditional baying systems. Users are no longer forced to fall back on an enclosure system different from baying suites when preferring to use free-standing enclosures as stand-alone solutions. Rittal’s SE 8 enclosures use the same accessories for standalone applications as with the TS 8 bayed enclosures.

Another advantage is the expertise available from system manufacturers relating to the planning and installation of the TS 8 system can be directly transferred to the new enclosures. Since the SE 8 and TS 8’s modular systems for interior installation are identical, planning can be started immediately. Decisions an be made at a later stage whether a free-standing or a bayed enclosure is needed.
Rittal’s SE 8 is a one piece monobloc, consisting of two side panels and a roof, all made from one piece of sheet steel. This makes handling easier, as there is no need to mount the side panels. The rear panel can be unscrewed for easy access to the enclosure. Cable entry solutions can be employed on the integrated base frame, as in the TS 8 bayed system. Doors and base/plinth of the SE 8 have also been adopted from the TS 8 programme.

These design options are interesting for switchgear and control system manufacturers. For instance, the SE 8 free-standing system enclosure now features automatic potential equalisation of the enclosure body with the rear panel and gland plates. Special contact elements, pushed into the surface coating during the assembly procedure, provide a secure and conductive electrical connection. This solution significantly reduces costs and assembly times.

Rittal’s SE 8 offers better possibilities for interior installation than its predecessor (the ES 5000) as expansion on two mounting levels is possible. This increases flexibility and provides additional space. The SE 8 offers major potential savings because larger enclosure widths of up to 1800 mm are possible. Free-standing enclosures do not have to use two bayed enclosures.

Both Rittal’s TS 8 and the SE 8 share the same climate control platform, from fan and filter unit to chiller, allowing simpler ordering and assembly due to cross-platform common mounting dimensions and output categories. The TS 8 modular climate control concept can be used without any limitations.
Economical alternatives with the same technology are possible when there is certainty that a particular unit is not going to be expanded and that a free-standing enclosure is sufficient. Rittal’s SE 8, using the same technology, is a reasonably priced alternative to a baying system.

Rittal SE 8 Enclosure

http://www.rittal.com/uk-en/content/en/unternehmen/presse/pressemeldungen/pressemeldung_detail_31552.jsp

Rittal Enclosures, Power Distribution, Climate Control, IT Infrastructure, Software & Services – http://www.rittal.co.uk

Rittal’s one-stop solution for human-machine interfaces

Human-machine interfaces play a key role when choosing manufacturing equipment. Potential purchasers not only consider the quality of the machine and the products it manufactures, but user-friendliness and a robust, well-designed operator control system, often influence decision-making just as much.

Engineering specialist Laempe & Mössner produce several lines of core shooters and equips its’ core shooting machines with Rittal’s support arm and housing systems.

A programmable logic controller manages all processes within the system and the human-machine interface comprises a panel PC with a touch screen. This enables the user to operate the equipment and to monitor current status. In addition to the panel PC, a number of other elements, such as an emergency off switch, signal pillars, valves and a pressure indicator, are required. All these components are contained in compact housings from Rittal’s Comfort Panel range.

Each housing is divided into three sections with the panel PC mounted in the centre, whilst the lower third accommodates the switches, signal pillars and other control and display elements. The top part contains pressure and vacuum indicators, plus valves to control the pneumatic and vacuum systems. This logical arrangement, coupled with a spacious housing layout, enables a significant degree of standardisation.

To mount the housing securely on the machine, a solution is based on Rittal’s CP 120 support arm system. The strength of the support arm system, a very robust and reliable product, was pivotal in choosing Rittal’s solution as this has been an area where problems have occurred with previous vendors’ products in the past.

CP Support arm.jpg-s

Rittal enclosures “the System”: Faster – Better – everywhere http://www.rittal.co.uk

Rittal’s new Adaptor for RiLine60

Rittal’s RiLine60, a fully shielded flexible busbar system with a wide range of busbar adaptors, has been extended to include a new OM adaptor ideally suited for the control panel manufacturer. Combining contemporary design and outstanding safety technology, with easy design and speedy installation, RiLine60 offers a safe method of distributing power within cabinets.

A cost effective solution for power distribution, the new OM adaptor with extended connecting cables is designed for control gear components with tension spring clamp terminals. The connection leads are 165mm (previously 130mm) enabling easier connecting and work with products such as: Allen-Bradley 140M-RC2E, Eaton PKZM0, Siemens S00 and Schneider Electric GV2.

Available are four configurations; long and short support frames, adaptor ratings of 16A and 32A and an adaptor width of 45mm.

OM Adaptors-s

RIttal enclosures – The System http://www.rittal.co.uk

Rittal make IT work for Sovereign

How to overcome the common problem of structural pillars or columns when designing a data centre space? Independent IT service and business solution specialist SDC (Part of the Sovereign Business Integration Group) encountered this challenge when developing their data centre in Hertfordshire.

Rittal offered the unique approach of incorporating the columns into the cabinets and cooling system. Fully sealing columns into cabinets and aisle containment systems can deliver improved efficiency in areas that are not conducive to efficient airflow, as well as utilising the maximum floor space available.
Completing phase two of the ground floor data hall, comprising of a further 80 Rittal TS IT Cabinets and 4 Cold Aisle pods, Rittal were able to solve the problem through a bespoke cold aisle pelmet based system. Cable management was used to good effect within the racks.

Cold aisle containment technology from Rittal maintains constant temperatures and precise humidity levels, ensuring all key functions are maintained.

Rittal Ltd Sovereign

Rittal Enclosures – The System. http://www.rittal.co.uk