Control Cabinet Engineering at HPS Using Eplan Cogineer

June 9, 2020

Control cabinet manufacturers who automate their planning processes will benefit from shorter project times and higher quality. Secondary processes such as documentation creation can also be simplified. But how much time really can be saved over a whole process? Hanseatic Power Solutions GmbH (HPS) automated its control cabinet engineering in several steps and has just implemented EPLAN Cogineer. The company has now used a “before and after” comparison to record actual time savings. The results are clear. Electrical planning alone now takes only 20% of the original time.

Emergency power supplies for power stations and “power islands” for hospitals and cruise ships are the type of applications for which control cabinets from HPS are constructed. The company plans and builds control technology for the highly demanding energy sector. This is evident from HPS opening a branch in the Arab Emirates in 2017. Employees there carry out sales, project planning and service tasks for customers from the region who include power plant and refinery operators.

Target: Maximal automation in control cabinet engineering

Since the company was founded in 2009, managing director Bernd Mähnss and his team have prioritised maximum automation in the project planning, design and manufacture of control cabinets. This has resulted in the completion of even complex projects (with 80 to 100 control cabinet panels) within six to eight weeks, from receipt of the order through to delivery and installation.

One reason for this quick turnaround, even though the projects involve batch size one products, is a consistent use of the EPLAN platform. EPLAN Pro Panel is used for 3D cabinet planning. Power distributors and busbars made of copper are designed and completed in 3D using the copper module, and (external) cable assembly is based on the routing module.

Quickly created schematics

HPS (and thus also its customers) has been benefiting from even shorter throughput times for several months now. When EPLAN launched its Cogineer software, HPS was one of the first customers to implement the module. EPLAN Cogineer enables the automated schematic creation without any programming required and without the need for specialist knowledge in configuration and variant management. Only basic macro knowledge is needed to quickly start using the application.

Standardisation also for one off products It may at first be surprising that a control cabinet manufacturer working with batch size one is using automation and standardisation. Bernd Mähnss, founder and managing director of HPS: “Our projects are of course always individual. But they also have recurring functions and modules such as schematics for  controlling ventilation and fire dampers in building automation”. For such functions, HPS stores macro libraries in Cogineer which electrical engineers can access when required. Dennis Burmeister, Sales Engineering/ Service at HPS and responsible for the implementation of Cogineer: “Users just need to select the required power and everything else is then determined automatically and integrated into the schematic: from the correct switches for motor protection and repair through to the terminals and cable cross-sections. Function designations in the schematic are also assigned automatically”. Options can also be clicked and integrated into the plan. For example, the power supply can be selected via generator voltage or via consumer voltage with contactor.

“Tried and tested”, including routing and thermal properties

Depending on the options selected and power supply type, schematics are then automatically generated. Cogineer also offers other benefits in addition to design automation. Dennis Burmeister: “The macros have been tried and tested and are error-free. This gives us assurance while also improving the quality of the design. Planners no longer need to carry out time-consuming detailed work when making subsequent changes, e.g. to a power value. The software takes over”. Routing is integrated in the automated schematic creation, and HPS can also automatically order the terminals directly from Phoenix Contact using the corresponding EPLAN module. Rittal Therm is used to calculate power dissipation of all the components selected in EPLAN. This enables the planner to identify “hotspots”.

The next step: Paperless production using EPLAN eView

 

For several years, HPS has not been using standard hard copy folders and documentation unless customers request them. Instead, a QR code is attached to each control cabinet enabling users to view online the detailed documentation maintained at HPS. Dennis Burmeister: “The added benefit is that the documentation is always up to date in the sense of it being a ‘digital twin’ throughout the entire lifecycle of the actual cabinet”. The next step is to have a paperless “shop floor” by using EPLAN eView. Bernd Mähnss: “We already only need the schematic for inspection. In production, a layout plan is sufficient. We will soon be equipping the inspection stations with eView. Maintenance personnel can then add com-ments directly in the standards-compliant documentation. This saves time and again avoids duplication of work”.

Summary: Automation enables major efficiency gains

After implementing EPLAN Cogineer, HPS used a “before and after” comparison of the time taken for processing an order with and without automation. Taken into consideration were Cogineer as well as EPLAN links to mechanical processing and automated cable and terminal assembly. These resulted in design being faster by 25%, and electrical planning by 80%. The effort required for the mechanical production is reduced to half, electrical production is 40% faster. Documentation was created in a quarter of the time it normally takes. Bernd Mähnss: “All in all, our delivery times – which were previously more than competitive, i.e. very short – have been reduced by around 35% thanks to automation and our integrated planning process. At the same time, documentation is more detailed and planning quality is also better because tried and tested macros and modules are being used”. It is therefore clear that HPS will continue along this path.

For more information, visit https://www.eplanusa.com/us/home/.

Related Articles


Changing Scene

  • Wesco Opens State-of-the-Art Facility in Eastern Canada to Support Influx of Megaprojects in the Region

    Wesco Opens State-of-the-Art Facility in Eastern Canada to Support Influx of Megaprojects in the Region

    Wesco International has recently announced the grand opening of a new state-of-the-art facility on Higney Avenue in Dartmouth, Nova Scotia, Canada, making this the largest facility of any distributor in the Atlantic region. The new building, facilitated by Touchette Real Estate, a division of Groupe Touchette, will feature Wesco’s comprehensive suite of services and solutions including… Read More…

  • PataBid Nominated for Canadian Choice Award in Software Services

    PataBid Nominated for Canadian Choice Award in Software Services

    PataBid is proud to announce its nomination for a Canadian Choice Award in the Software Services category. This recognition highlights PataBid’s commitment to supporting the electrical contracting community across Canada by providing innovative estimating software solutions that streamline estimating processes and ensure predictable and profitable projects. Read More…


Sponsored Content
The Easy Way to the Industrial IoT

The way to the Industrial IoT does not have to be complicated. Whether access to valuable data is required or new, data-driven services are to be generated, Weidmuller enables its customers to go from data to value the easy way. Weidmuller’s comprehensive and cutting-edge IIoT portfolio applies to greenfield and brownfield applications. Weidmuller offers components and solutions from data acquisition, data pre-processing, data communication and data analysis.

Visit Weidmuller’s Industrial IoT Portfolio.


ADVANCED Motion Controls Takes Servo Drives to New Heights (and Depths) with FlexPro Extended Environment Product Line

Advanced Motion Controls is proud to announce the addition of six new CANopen servo drives with Extended Environment capabilities to their FlexPro line. These new drives join AMC’s existing EtherCAT Extended Environment FlexPro drives, making the FlexPro line the go-to solution for motion control applications in harsh environments.

Many motion control applications take place in conditions that are less than ideal, such as extreme temperatures, high and low pressures, shocks and vibrations, and contamination. Electronics, including servo drives, can malfunction or sustain permanent damage in these conditions.

Read More


Service Wire Co. Announces New Titles for Key Executives

Bruce Kesler and Mark Gatewood have been given new titles and responsibilities for Service Wire Co.

Bruce Kesler has assumed the role of Senior Director – Business Development. Bruce will be responsible for Service Wire’s largest strategic accounts and our growing Strategic Accounts Team.

Mark Gatewood has been promoted to the role of Vice President – Sales & Marketing. In this role, Gatewood will lead the efforts of Service Wire Company’s entire sales and marketing organization in all market verticals.

Read More


Tri-Mach Announces the Purchase of an Additional 45,000 sq ft. Facility

Tri-Mach Elmira Facility

Recently, Tri-Mach Inc. was thrilled to announce the addition of a new 45,000 sq ft. facility. Located at 285 Union St., Elmira, ON, this facility expands Tri-Mach’s capabilities, allowing them to better serve the growing needs of their customers.

Positioning for growth, this additional facility will allow Tri-Mach to continue taking on large-scale projects, enhance product performance testing, and provide equipment storage for their customers. The building will also be the new home to their Skilled Trades Centre of Excellence.

Read More


JMP Parent Company, CONVERGIX Acquires AGR Automation, Expanding Global Reach

Convergix Automation Solutions has completed the acquisition of AGR Automation (“AGR”), a UK-based provider of custom, high-performance automation design and systems integration primarily to the life sciences industry.

Following Convergix’s acquisitions of JMP Solutions in August 2021 and Classic Design in February 2022, AGR marks the third investment in Crestview’s strategy to build Convergix into a diversified automation solutions provider targeting the global $500+ billion market, with a particular focus on the $70 billion global systems integration and connectivity segments. Financial terms of the transaction were not disclosed.

Read More


Latest Articles

  • How Advanced X-Ray and AI Inspection Technologies Optimize Quality Control and Reduce Costs in SMT Manufacturing

    How Advanced X-Ray and AI Inspection Technologies Optimize Quality Control and Reduce Costs in SMT Manufacturing

    Explore how Omron’s latest X-Ray machines and AI-driven solutions are setting new standards in manufacturing efficiency and quality control. The manufacturing landscape is swiftly evolving, and Omron is at the forefront with its innovative PCB inspection machines. These systems offer profound insights into SMT production process, enhanced quality control, and can significantly reduce labor costs. Advancements… Read More…

  • KUKA Establishes New Software and Digital Business Segment

    KUKA Establishes New Software and Digital Business Segment

    Software is playing an increasingly important role in mechanical engineering. What used to be mostly solved mechanically is now done by electronics and the associated software. “With KUKA Digital, we are expanding our offering in order to position ourselves broadly for a market with strong growth potential. Our customers need products, solutions and consulting approaches to digitalize… Read More…