Case study
Manufacturing of 110 electrical control cabinets for new production lines
Who was the client and what was the challenge?
The plant belongs to a global automotive group and manufactures components for its worldwide network of production facilities.
As part of the plant expansion, the client installed seven entirely new production lines, including press lines, and required a reliable manufacturer of power distribution and control systems.
Project Objectives
1. Complete Power Distribution and Control System
Design and manufacture of control cabinets and power distribution cabinets for the new production lines.
2. Improved Operator Convenience
Design of ergonomic operator panels to ensure intuitive operation of complex manufacturing processes.
3. High-Volume Production
The order included the manufacture of 110 electrical control cabinets within a tight schedule while meeting stringent inspection and acceptance requirements.
How the electrical panel manufacturing process
was carried out
Process and implementation
- The project covered the complete manufacturing of electrical control cabinets—from mounting plate preparation and panel assembly, through equipment installation, wiring, and busbar machining, to Factory Acceptance Testing (FAT).
- Thanks to our high manufacturing capacity, we were able to produce multiple types of control and power distribution panels simultaneously.
- The scale of the project and the variety of production lines required precise coordination and exceptional manufacturing flexibility
- The operator panels were designed with a strong focus on ergonomics and ease of use. Due to the large number of control devices, the operator panels reached dimensions comparable to those of the electrical enclosures themselves.
- A mobile Rittal machining center was used for copper busbar processing in the main power distribution panels, ensuring high precision and repeatability throughout the manufacturing process.
- Production was completed at our manufacturing facility within two months, utilizing our available production capacity of up to 4,500 man-hours per month.
- Every electrical cabinet underwent comprehensive electrical and functional testing before delivery.
- The project concluded with successful internal technical inspections and final acceptance by the end customer.
The main challenges during the project
- Manufacturing complex three-pole connections in high-power distribution cabinets.
The high power ratings of the power distribution systems required precise machining and assembly of copper busbars while ensuring the highest quality of electrical connections.
2. Integration of large and highly customized operator panels.
The operator panels were equipped with a large number of control devices, requiring careful layout design with a strong focus on ergonomics and intuitive operation.
An additional challenge was the implementation of extensive panel wiring while maintaining clarity, high assembly quality, and the overall reliability of the system.
Technologies and Solutions
Project Results
On-time manufacturing and prefabrication of 110 electrical cabinets for seven production lines
Successful final acceptance with the participation of the end customer
Highly ergonomic and functional operator panels
Full compliance with the requirements of the German project partner
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