Prefabrication of control cabinets: Aspects, processes and realisations
Prefabricated control cabinets form the foundation of industrial automation, enabling the creation of advanced control systems. These systems are indispensable for monitoring, regulating and managing the operation of machinery and equipment, which makes them a key element in many industrial plants. Thanks to the prefabrication of control cabinets, all the necessary components – such as:
- PLCs,
- operator panels,
- controllers
- signalling devices
- protections,
- electrical and mechanical connections
– are integrated in a single, tidy location.
One of the main advantages of prefabricating control cabinets is the increased safety of machine operation. The process effectively minimises the risk of downtime, as well as quickly identifying and rectifying potential failures. Prefabrication covers a wide range of activities, such as:
- design,
- assembly
- commissioning,
– with full consideration of the customer’s individual needs. This ensures that each control cabinet is perfectly tailored to the specific requirements of the plant in question.
Testing and quality control is another extremely important element of prefabrication. This allows any faults to be detected and repaired even before the product is delivered to the customer, thus ensuring the reliability and long service life of the control systems. Prefabrication of control cabinets not only facilitates the management and maintenance of equipment, but also contributes to the optimisation of production processes, which is crucial in a dynamic industry.
What is prefabrication of control cabinets?
Prefabrication of control cabinets is a key element of industrial automation. It involves the creation of advanced control systems that are essential for monitoring, regulating and controlling the operation of machinery and equipment in industrial plants. Thanks to this process, it is possible to significantly increase safety and operational efficiency. In a dynamic industry, this is of great importance.
The process involves the design, installation and testing of control systems, tailored to the specific needs of the plant in question. The control cabinets resulting from this process are at the heart of the electrical infrastructure in many production facilities. Where production lines, machines or complex installations require precise electrical solutions, the prefabrication of control cabinets is essential.
Definition and importance in industrial automation
Industrial automation deals with the automation of production processes, and the prefabrication of control cabinets is an integral part of this. Control cabinets and electrical switchgear are key components in industrial applications, enabling precise control of machine operation. They make production processes faster, safer and more efficient.
The prefabrication of electrical cabinets in industrial automation allows precise control and monitoring of machine operation, which is essential for maintaining production continuity and minimising the risk of failure. In this way, control cabinets not only manage processes, but also ensure their reliability. This is crucial for the operational stability of plants, directly influencing safety and efficiency.
The role of control cabinets in industrial plants
In industrial plants, control cabinets play a fundamental role in managing the operation of machinery and production processes. They make it possible to control the operation of devices such as:
- industrial robots,
- conveyors
- compressors,
- fans.
The prefabrication of control cabinets is particularly important for plants in need of reliable and efficient solutions to control their operations.
The use of control cabinets in industry allows production processes to be optimised, resulting in increased productivity and reduced operating costs. Companies can thus better manage their resources and respond more quickly to changing market needs, gaining a competitive advantage.
Prefabrication process for control cabinets
The prefabrication of control cabinets is a complex process, involving several key stages – from the initial design to the final commissioning of the finished system. A thorough understanding of the customer’s needs is essential at the outset . This phase allows a solution to be created that is perfectly tailored to the specific requirements of the plant.
It then moves on to the assembly of components, such as:
- PLCs,
- operator panels,
- controllers,
- alarms,
- safety devices.
Each of these components plays a key role in ensuring the smooth and trouble-free operation of the entire system.
Testing and quality control are an integral part of prefabrication. They make it possible to detect and rectify any faults before the enclosure is delivered to the customer. This process includes functional tests and a detailed quality check of the assembly and wiring. Prefabrication is not only the assembly of components, but also a comprehensive approach to creating reliable and efficient systems, ready for immediate use.
Manufacturing steps for prefabricated cabinets
The manufacture of control cabinets consists of several key stages:
- Assembly and wiring of components – the precise connection of components such as PLCs, operator panels, controllers and annunciators is essential for the system to function correctly.
- System configuration – allows functions to be customised to meet specific customer requirements.
- Quality testing – includes checking the functionality of all components and checking the quality of assembly and wiring.
This enables any faults to be detected and repaired before the product is delivered to the customer, guaranteeing the reliability and long-term operation of the control systems.
Component assembly: PLCs, operator panels and others
A key stage in the prefabrication of control cabinets is the installation of components such as PLCs and operator panels. PLCs (Programmable Logic Controllers) are responsible for controlling the operation of machines and equipment in industrial automation systems, enabling precise management of production processes.
Operator panels allow operators to control and manage the operation of machines. Other components are also installed in control cabinets, such as:
- regulators,
- signalling devices
- safety devices,
- inverters,
- contactors.
Each of these components is essential to ensure the correct functioning of the entire system.
Testing and quality control
Testing and quality control are indispensable steps in the prefabrication process of enclosures. A key test is the FAT (Factory Acceptance Test), which allows the functionality of the enclosure to be checked before delivery to the customer. The tests include quality checks on the assembly, wiring and operation of all components.
Thanks to the rigorous testing, any defects can be detected and repaired before the product is delivered to the customer. This ensures that each control cabinet is fully functional and ready for immediate use, which is key to ensuring the reliability and long-term operation of control systems.
Use of prefabricated control cabinets
Prefabricated control cabinets are widely used in many industries. They are found in the manufacturing, food, automotive, heavy industry, energy, transport and building automation industries. They make it possible to effectively manage the operation of machines and systems in factories, on production lines and in water supply, air-conditioning or energy systems. Their versatility makes them an indispensable component of modern technologies, supporting the efficiency and safety of processes.
Control cabinets for production lines
On production lines, prefabricated control cabinets play a key role in the management and regulation of machinery. They are indispensable for controlling industrial robots, conveyors and other equipment, thus optimising production processes. Precise control translates into greater production efficiency and a lower risk of breakdowns, which is crucial for the uninterrupted operation of plants.
Control cabinets for renewable energy systems
Prefabricated control cabinets are used in renewable energy systems such as photovoltaic installations or wind power plants. They are responsible for controlling the operation of the equipment in these systems, which is key to their efficient and safe operation. They enable better management of energy resources, supporting sustainable energy sources and environmental protection.
Control cabinets for potentially explosive atmospheres (Ex zones)
In explosive atmospheres, or so-called Ex Zones, prefabricated control cabinets must comply with strict safety standards, such as ATEX standards. They are designed to prevent explosions and other hazards, which is essential for safety in high-risk areas. They are a key element in the safety management of the chemical, petrochemical and other sectors with explosion risks.
Standards and directives for the prefabrication of enclosures
The prefabrication of control cabinets must comply with a number of standards and directives to guarantee the safety and reliability of control systems. Key standards are EN 61439-1:2011 and the Machinery Directive 2006/42/EC, which specify construction and safety requirements. Adherence to these standards is indispensable for control cabinets to function as expected and comply with current legislation.
Standard PN-EN 61439-1:2011 - construction requirements
The PN-EN 61439-1:2011 standard defines the construction and safety requirements for low-voltage switchgear and control cabinets, including control cabinets. Compliance with this standard ensures that prefabricated control cabinets are designed and built to the highest quality standards. Users can rest assured that their systems are functional and safe for everyday use.
Machinery directive 2006/42/EC - Design rules
The Machinery Directive 2006/42/EC lays down rules for the design and construction of machinery, including control cabinets, with emphasis on ergonomics and safety. Compliance with this directive ensures that control cabinets are designed to minimise risks to operators and other users. Ergonomic solutions increase safety and improve efficiency, which is important in dynamic industrial environments.
EMC Directive 2014/30/EU
The Electromagnetic Compatibility Directive 2014/30/EU addresses the electromagnetic compatibility requirements for equipment, including enclosures. Prefabrication must take these requirements into account to ensure immunity to electromagnetic interference and prevent its generation. Compliance with the directive is crucial for the interference-free operation of control cabinets in complex industrial environments, which is essential for the continuity and reliability of production processes.
Prefabrication of electrical switchboards
Prefabrication of electrical switchgear is the heart of industrial automation. It includes the design, installation and testing of low-voltage switchgear, which plays a key role in power distribution and ensuring the safety of systems. Switchgear is the focal point of the electrical infrastructure, enabling the smooth management of energy flow in industrial plants.
The prefabrication of control cabinets also includes the prefabrication of electrical switchgear, enabling the creation of complex systems to control and protect the operation of machinery and equipment. In this way, the prefabrication of electrical switchgear significantly increases the reliability and efficiency of production processes.
Differences between control cabinets and electrical switchgear
Although control cabinets and electrical switchgear appear in similar contexts, their functions in industrial automation are different:
- Electrical switchgear – a set of low-voltage devices, such as switches, regulators or signal devices, responsible for power distribution and system safety.
- Control cabinets – focus on the control and management of machine operation.
Prefabrication of control cabinets also includes the creation of electrical switchgear, enabling the integration of control and power distribution functions in a single system. This allows the development of advanced and efficient solutions, ideally suited to the specific needs of industrial plants.
Prefabrication process for low-voltage switchgear
Prefabrication of LV (low-voltage) switchgear requires precise design and assembly. Every step, from the selection of components to final testing, is of paramount importance to ensure the reliability and operational safety of the switchgear. This process involves customising the switchgear to meet the customer’s individual requirements, allowing its functions to be optimised for the specific application.
Prefabrication of LV switchgear provides an opportunity to introduce innovative solutions, significantly improving the energy efficiency and safety of electrical systems in industrial plants.
Refurbishment and service of control cabinets
In the fast-changing world of industry, upgrading and servicing control cabinets is key to maintaining the efficiency and safety of automation systems. Cabinet service includes not only regular inspection and maintenance, but also upgrading existing systems to meet new technological requirements and safety standards.
Modernisation of existing control cabinets
The modernisation of control cabinets makes it possible to adapt current systems to modern technological requirements and safety standards. A key element is the replacement of obsolete components with modern, efficient and safe solutions. Prefabrication of control cabinets also includes modernisation, which means that existing cabinets can be adapted to new needs without having to completely replace them, saving time and resources.
In industrial automation, modernising control cabinets is not just about replacing components, but also optimising the entire system. Companies can thus:
- Increase the efficiency of production processes,
- Minimise the risk of breakdowns and downtime,
- Manage resources better,
- Respond more quickly to changing market needs.
This is crucial in today’s competitive reality, where flexibility and efficiency determine success.
Service and maintenance of control cabinets
Regular servicing of control cabinets is fundamental to ensuring their reliability and long service life. It includes technical inspections and maintenance, allowing potential faults to be detected and repaired early. This avoids costly downtime and ensures production continuity, which affects the profitability of the company.
Cabinet maintenance is also an opportunity to make improvements, improving productivity. Regular servicing keeps cabinets in optimum technical condition, essential for:
- The operational safety of machinery and equipment,
- Efficiency of automation systems,
- Stability of production processes.
Companies can thus enjoy stable and safe operation of their automation systems, which translates into long-term operational success.
Benefits of prefabrication of control cabinets
The prefabrication of control cabinets brings many benefits – both in terms of efficiency and safety. It improves the quality and reliability of systems, significantly reduces costs and shortens project times. It enables every enclosure function to be thoroughly tested before installation, minimising the risk of failure and ensuring long-term, trouble-free operation.
Improving efficiency and safety
The key benefit of prefabricating control cabinets is to improve the efficiency and safety of machine operation. It enables the rapid detection of faults and the prevention of downtime, which is of great importance in dynamic industrial plants. Prefabrication allows the standardisation of components, making it easier to manage and maintain systems, which translates into a higher level of operational safety.
Reduction in costs and lead times
Prefabrication of enclosures reduces costs and project times. Standardisation and automation of the process makes on-site assembly faster, resulting in lower operating costs. It allows better planning and organisation of work, crucial for efficient project management. Outsourcing the prefabrication of control cabinets is a cost-effective solution for companies looking to optimise their production processes.
Prefabrication of control cabinets for various industries
Prefabricated control cabinets are used in many sectors, adapting to the specific requirements of each industry. It is used by all those who need reliable systems to control and manage the operation of machinery and equipment. From the food industry to transport, prefabricated control cabinets are a key component of modern technological infrastructures, ensuring stability and operational safety.
Applications in the food and heavy industry
In the food and heavy industry, the prefabrication of control cabinets plays a key role in ensuring smooth and safe production processes. These cabinets control the operation of machines and systems, essential for maintaining high product quality and production efficiency. Modern technology enables precise monitoring and regulation of processes, resulting in cost optimisation and increased productivity.
- In food processing plants, control cabinets monitor temperature and humidity, influencing product quality.
- In heavy industry, they ensure the safety and reliability of machinery operation, crucial for production continuity.
Use in air conditioning and water supply systems
Prefabrication of control cabinets includes the creation of systems for air conditioning and water supply systems, crucial for managing the operation of pumps and other equipment. In water supply systems, they control the flow of water, ensuring its constant availability and quality. In air-conditioning systems, they enable precise regulation of temperature and humidity, essential for user comfort and energy efficiency in buildings.
- In large office buildings, control cabinets can reduce energy consumption, ensuring optimal working conditions.
- In water supply systems, they guarantee an uninterrupted supply of water of adequate quality.
Applications in transport and energy systems
In the transport sector, the prefabrication of control cabinets is indispensable for managing systems such as traffic lights, railway automation, lifts or escalators. These cabinets increase safety and ensure the smooth flow of traffic, crucial for the operation of transport infrastructures.
- In energy systems, they control the distribution of energy, essential for stability and reliability of supply.
- In power plants, they monitor and regulate the flow of energy, minimising the risk of breakdowns and supply interruptions.
Prefabrication of control cabinets is not only a technology, but above all a strategic approach to process optimisation in industrial automation. It enables companies to enjoy increased efficiency, reliability and safety of their systems. Investing in prefabricated control cabinets translates into real savings and competitiveness in the market.
As experienced specialists in industrial automation, we understand our customers’ needs very well. We offer comprehensive solutions tailored to individual requirements, ensuring the highest quality and compliance with current standards. Our prefabricated control cabinets are a guarantee of long-term and trouble-free operation.
We invite companies looking for reliable and modern solutions for industrial automation to work with us. Together, we can build systems that lay the foundations for the success and growth of your business.