Rationalizing Electrical Installation Technology Don’t throw money down the drain!

In electrical installations decisions are made in the early stages that ultimately result in hidden cash drains. By using system-oriented concepts and decentralized automation technology such financial consequences can be avoided. Murrelektronik’s approach keeps cost savings at the forefront of these early decision-making stages. By looking at the whole system from the start, we focus on how to increase standardization and efficiency in the electrical installation. Meaning that Murrelektronik can provide electrical installation solutions that reduce costs by up to 30%.

The three scenarios below demonstrate that electrical installation technology cannot simply be an afterthought. It must be an intentional engineering consideration and factor into the calculations for overall costs.

A long time ago, electrical installation played a classic role in machine construction. All of the control technology was placed in the control cabinet and connected to sensors and actuators in the field via large terminal blocks. The individual components – whose compatibility determined how error-prone the system was – came with expensive installation and commissioning tasks that had to be repeated from one machine to another. Standardized plug connections were rare and, when they did exist, they had to be manually configured, a tedious process.

More recently, power and data were distributed in separate terminal boxes on the machine periphery. This moved the classic parallel wiring method from the control cabinet to the field. While this did lighten the installation workload slightly, the additional terminal levels meant there were more sources of potential errors as well as wiring errors between the control cabinet and the periphery.  This led to the difficult and time-consuming task of troubleshooting in the event of short circuits and overloads resulting in long stretches of downtime and production failures.

These days, the IO level is located in the vicinity of the process – at the sensors and actuators. This significantly reduces the size of the control cabinet. The benefits of this method include plug-in system components and molded, fully tested connectors that are IP67 rated, vibration resistant and come in a variety of lengths. Electrical installations are simpler and take significantly less time to install. Wiring errors are virtually eliminated, making the commissioning process quicker and less frustrating all around.

So, what does the future hold? No matter how far ahead you look, it is impossible to achieve significant cost savings without taking a systematic approach and using installation technology in a targeted way. Murrelektronik’s tailor-made concepts and components not only can reduce overall costs by up to 30% but also allow systems to benefit from technological progress including innovative diagnostics functions – added value for both mechanical engineers and machine operators alike.

Installation costs using a series machine as an example

Caption: Decisions made at the start of the engineering process ultimately determine over two-thirds of the costs generated during machine construction. There is also great potential for savings in special machines.

A holistic approach now to avoid cash drains later

Everyone, from purchasing and design to installation and commissioning teams, can help to reduce overall machine costs by taking a holistic, systematic approach and using installation technology in a targeted way. If all parties recognize that installation technology is the core driver of cost efficiency, then planning, construction and production can be more flexible, less complex and ultimately more efficient.

Is there a case for a “plug and play” IP67 field installation instead of costly terminal boxes? Would standardized, preconfigured components (from a smaller number of suppliers) allow for a coordinated system solution? Can PLC I/O assemblies be replaced by decentralized fieldbus I/O modules? Can complex cable bundles and trays be avoided by placing distribution boxes near the sensors and actuators? Are plug-in, molded cable connections being used in place of single conductors to terminals to allow for faster, less error prone installation, servicing and maintenance? How might user-friendly diagnostics increase system availability for the operator?

Connectivity as a Key Technology

Murrelektronik has the answers to these questions as well as sophisticated solutions for each customer. Installation technology for machines and systems can take many shapes. Efficient installation technology planned for each application and designed with a system-oriented view opens up the potential for enormous savings, which makes the decision-making process easier. A systematic approach certainly falls within the scope of responsibility of the mechanical engineers and technicians, but also shows managers and executives how to avoid cash drains.

Murrelektronik works with the customer to identify untapped opportunities and release the potential in systematic thinking. In turn, the approach often increases machine availability and leads to more simplified installation technology and smarter diagnostics.

The Murrelektronik System Specialist are available to help you test out their holistic approach to system design. See where the promised 30% savings can be found!

Call 0161 8728 3133 or email the UK team on [email protected]

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