Optimising Control Panel Enclosure Flexibility
Processing facility managers are under pressure to manage their space to minimise capital and operational expenses . The need to fit more equipment into an existing space prompts machine designers to reduce the size and footprint of the machines , which challenges the control engineers to design and build control panels within a constrained footprint .
Designing smaller control panels , control engineers need to consider several variables : cable segregation , thermal management , cable entry , electromagnetic interference ( EMI ), and cable bend radius , not to mention allowing extra space for future additions . A control engineer ’ s job is further complicated by safety considerations such as arc flash hazards , standards compliance , and minimum separation requirements for electronic components .
START WITH ENCLOSURE FLEXIBILITY
Selecting the proper control enclosure is an essential factor when space optimisation is the objective . Enclosures are designed to support a variety of accessories that facilitate component mounting based on the targeted application .
Choose an enclosure platform that allows full utilisation of the space between the enclosure door and components mounted to the sub-panel in the rear of the enclosure . To accomplish this , the enclosure must be designed to support structural members along the sides , top and / or bottom , as well as on the door .
A designer requires full use of the interior for component mounting and cable and
30 FDPP - www . fdpp . co . uk wire management . Enclosures need a full side mount panel with additional wire duct , relays , and grounding provisions that would have been mounted on the rear sub-panel . This design reduces the wall or machine space by 20 % compared to a more common sub panel mounted design .
There are several products available to help control engineers utilise this 3D space , as well as often underutilised corner space in control panels that use traditional side equipment mounting plates .
DIN rail wiring ducts with two separate wiring channels enable the user to mount a DIN rail with components that would typically be installed directly to the subpanel , potentially saving 30 % of the space on a sub-panel . Corner wiring ducts can provide good wiring transition from rear sub-panels to side sub-panels while reducing the amount of sub-panel space needed by 12 %.
Today ’ s EMI noise shielding allows wiring that would normally require six inches of separation to be much closer together . Panduct PanelMax Shielded Wiring Duct and Noise Shield separate noisy motors and drive cables from sensitive Ethernet or control cables and reduce the space required .
Also consider minimising the external footprint . One consideration is the control panel mounting position . Flexibility with
the mounting allows the control panel anywhere in the design , creating an integrated system solution .
When the enclosure houses valuable mission-critical equipment or information , space optimisation may take a back seat to control panel security . An investment in the right security will be less than the cost of a potential loss , but the protection needed can vary . The expense of lost or stolen data or the cost of injury from unintentional access can be mitigated with a layered approach to controlled access .
Access control and power distribution capabilities typically associated with building security can now be integrated directly into network enclosures . Electronic swing handles and built-in low frequency card readers limit access to critical IT equipment to authorised personnel . Intelligent power distribution units enable remote monitoring capabilities and improve efficiency by continuously analysing for electrical overloads and other conditions that place critical IT / OT equipment at risk .
CONCLUSION
Control engineers must overcome complexity when designing control panels in industrial environments . Whether the application is in oil and gas , food , automotive , water treatment , or pharmaceutical , competing design criteria influence decisions about optimising the control panel . Space optimisation can provide more design flexibility both for the control panel itself and the plant floor and help facilitate integrated access control solutions .
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