Industry 4.0 Manufacturing

The new 250 million-euro Rittal plant in Haiger embraces the principles of Industry 4.0.

It represents the company’s largest-ever single investment, enabling them to establish the world’s most advanced manufacturing facility for its new compact and small enclosures.

The plant’s highly automated production processes – working in conjunction with the neighbouring distribution centre (GDC) – enable seamless order fulfilment, guaranteeing ongoing availability of standard products and accessories.

Rittal is putting Industry 4.0 theory into practice. 

The world’s leading provider of solutions for enclosures, power distribution, climate control and IT infrastructure (as well as corresponding software and services) is creating a smart factory which will become the world’s most advanced production plant for compact and small enclosures.

“The plant will be fully aligned with highly efficient Industry 4.0 principles,” states Professor Friedhelm Loh, Owner and CEO of the Friedhelm Loh Group.

“The new manufacturing site will also safeguard future competitiveness for our customers and our own business. The total investment of 250 million euros is a positive statement in terms of the regional economy and the 290 jobs at our Haiger plant. We have quite consciously decided to proactively shape the future with the local people who made us what we are today.”

The new factory halls cover 24,000 square metres of floor space and will soon house more than 100 high-tech machines.

Around 9,000 AX compact and KX small enclosures will be manufactured every day, processing approximately 35,000 metric tons of steel annually.

Manufacturing in a smart factory

The equipment will be highly automated, producing individual items which are then assembled with exceptional efficiency.

In the past, individual steps such as cutting to size, edging, welding and painting were transactional, sequential and independent of one another. In the new era, all workers, machines and materials will be increasingly integrated into the manufacturing execution system.

At the end of the process, the individual assemblies are automatically merged and a QR code is applied, for easy identification and onward processing by the customer.

Both the machines and handling systems communicate with each other and with higher-level control systems via modern industry 4.0-capable communication networks.

Materials and components will be moved using 20 automated, guided vehicles. Packaging, marking and transfer to the distribution centre are managed automatically. Knowledge-based “learning” systems will enable predictive maintenance, preventing faults from occurring and minimising downtime.

Automated order management and fulfilment will guarantee the ongoing availability of standard products and accessories in the nearby global distribution centre, creating an end-to-end digital process chain – from configuration and engineering on the part of the customer, to shipment of the end-product.

A new world of work in Haiger

The new era of industrial manufacturing will also usher in major changes for the associated manpower.

There will be fewer strenuous manual tasks, such as lifting and carrying; instead, the focus will shift to controlling, monitoring and fine-tuning processes.

“The expertise and capabilities of experienced employees are one of the keys to the success of smart factories: systems can only learn and gain intelligence if they are taught systematically by humans,” explains Professor Loh.

Rittal proactively develops the digital skills of its workforce through training courses held at the Loh Academy.

The new technologies will bring improvements to the working environment as a whole. The Haiger facility will be quiet, clean and energy-efficient. For example, waste heat from the new paint shop will be recovered and reused, e.g. for degreasing components or for heating the factory halls. Efficient use of water is also a high priority. Process water is managed within a closed-loop system, where it is cleaned and reused.

Digital value creation at the customer organisation

Rittal will be manufacturing its new AX compact and KX small enclosures at the new plant.

Digital transformation has created new challenges in terms of the products themselves, the operating environment, and its availability. Rittal has therefore rethought and redesigned this offering inline with the imperatives of Industry 4.0.

Rittal provides effective support for the entire value chain for the production of panels and switchgear, from engineering to ordering to automation. Its digital product twin delivers high-quality data for the entire design, configuration and manufacturing process. This approach for the new AX and KX range echoes the successful launches of the Blue e+ cooling units and VX25 large baying enclosures.

Digital transformation is vital to business success

The Haiger facility is a pilot for the real-world implementation of Industry 4.0 and will act as a role model for Rittal’s international operations.

It will also be a pioneer and reference for Rittal’s own products and services in terms of the Industrial Internet of Things (IIoT).

Blue e+ cooling units further increase energy efficiency and are integrated into the monitoring and energy management systems via the IIoT interface. The entire machine park permanently provides data from the control system and the current operating states.

Production systems in the new factory deliver an ongoing source of actionable data on their operational status. In future, this information will be collected by an on-site edge data centre and analysed using powerful applications developed by sister company Innovo.

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Reducing Space with the RiLine 60 PLS 800 Busbar System

When designing a busbar system or control panel, space is always a consideration. Rittal’s customer EIS-Axon overcame the space restrictions for a major project for an airport baggage system using Rittal’s RiLine 60 PLS800 busbar system. With a busbar support that clamps the special shaped copper bar from underneath, which allows component adaptors to fit on top of the supports. This enabled an extra 80 mm of usable busbar for component adaptors.

The RiLine 60 PLS 800 busbar system is easy to fit, saving time and no worry of the busbar supports clashing with component adaptors.

Find out more by visiting: https://www.rittal.com/com-en/product/list.action?categoryPath=/PG0001/PG0229STV1/PG0300STV1/PG0313STV1&redirect=sps-riline

Bus Bar

Rittal Systems Ideally Suited to Switchgear Marine Applications

Rittal’s systems, from housing and enclosure systems, to climate control solutions and to power distribution systems and IT infrastructure solutions, are used by maritime operators across the globe. 

These include large numbers of shipyards, ships, harbours, offshore platforms and inland, with clients that include the major ships’ chandlers and shipyards.

The choice of Rittal as a partner is typically driven both by the high quality of its portfolio – easily sufficient to cope with the most demanding of marine environments – and by its consistent systems approach, which extends from project planning to implementation.

Just recently, Rittal’s products were featured in the refurbishment of the Nesserland lock in Germany, which has acted as a gateway to the inland port of Emden for more than 100 years.  The work included a new road bridge built over the lock for vehichles to cross which is also designed to open whenever ships need to enter the port.

Power to the system was supplied via three low-voltage switchgear systems housed in Rittal enclosures, and included NH slimline fuse-switch-disconnectors from Rittal’s RiLine busbar range.  Rittal IT racks accommodate the system’s complex network technology, with its free-standing enclosures housing the complex automation and safety technology.

The system at Emden is designed such that the individual functions of the lock and the bridge are networked together.  As such, it requires complex automation which is essentially controlled across three different locations: the main engine room; the engine that drives the bridge and the emergency control station which sits above that.

Mark Guest, Rittal Product Manager for IT Power Distribution says: “International maritime switchgear construction specialists are typically very loyal Rittal customers, not least because of our focus on value creation from engineering through construction to final application.

“For switchgear manufacturers, Rittal offers a combination of high product quality and a renowned system concept, around which all our solutions are based. This extends from our range of accessories, which are quick and easy to access, to engineering tools (such as EPLAN Electric P8 and EPLAN Pro Panel) and its Perforex machining centres.

“It means production times can be minimised while project leaders can react fast to any changes to the original specifications, swapping enclosures around if the project requirements change.”

Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.

Reducing the Energy Output of Machine Tools

Rittals_Blue_e+_Chiller

No business should ever underestimate the large amount of energy consumed by machine tools.  Cooling enclosures and spindles alone commonly account for more than 15 per cent of a company’s annual energy bill.

A test installation at a CNC lathe has demonstrated that Rittal Blue e+ chillers significantly reduce energy consumption while also being simple and easy to use. 

Bosch Rexroth AG, a long-established global manufacturing company, runs an energy efficiency consultancy called GoGreen at its headquarters in the Bavarian town of Lohr am Main.

GoGreen’s purpose is to examine and improve the energy efficiency of the company’s production plants worldwide. To this end, GoGreen works closely with institutes, as well as technology partners such as Rittal, to test possible solutions.

One of the most important research projects which GoGreen is involved in is the “Eta-Fab” (energy efficiency, technology and application centre) project at the Technical University of Darmstadt.

The project is headed by the University’s Institute for Production Management, Technology and Machine Tools (PTW); a facility that can closely replicate conditions and processes used in the Rexroth plant in Elchingen, allowing effective and accurate testing of potential innovations in areas such as improving the energy efficiency of machine tools.

Retrofitting CNC lathes

Among the products made at the Elchingen plant are hydraulic pumps and motors for mobile machines.  Many of the components for the hydraulic power units are manufactured on a CNC lathe which has a total connected load of 75 kVA and runs for up to six days a week in three-shift operation.

CNC lathes need their spindles to be cooled to dissipate the heat generated by the drive technology – and this is typically achieved through liquid cooling.

The GoGreen team examined what would be the impact of replacing the existing compressor cooling unit on the lathe, with a new Rittal Blue e+ Chiller.  The Blue e+ delivers the cooling medium and its DC compressor, controlled by an inverter, generates the necessary cooling output in the chiller. A circuit then transports the cooling medium to the spindles.

An impressive increase in energy efficiency

The test demonstrated that the Blue e+ could reduce energy consumption significantly.  Leo Pototzky, GoGreen Project Manager, Bosch Rexroth, said of the trial:   “The Rittal Blue e+ chiller consumes 50 per cent less electrical energy than the old chiller, while the saving achieved by the cooling unit in the enclosure even exceeded 80 per cent. This example shows us that a great potential still exists in many sectors.”

Ease of Use

The trial also highlighted how easy the Blue e+ is to operate.  The control panel with its touch display communicates to operators in plain text, and in up to 21 different languages.  This means that operators receive clear information and updates in status, which allows them to respond quickly to any issues.

The Blue e+ App communicates with the cooling units via NFC (Near Field Communication, an international transmission standard based on RFID technology for contactless data exchange), allowing important information to be transmitted wirelessly; a functionality which is especially important when a number of chillers have been configured.  It allows operators easy operational oversight and facilitates a swift response, if required.

Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.

 

LCP Solutions for Edge installations

For the implementation of space restricted or EDGE installs, the Liquid Cooling Package “Rack” variants are the perfect solution.

These variants deliver up-to 53kW of cooled air directly to the front of the rack, which means when combined with a glazed door you have a miniature cold aisle!

This allows the flexibility to install your equipment where it’s needed, whether this is next to a production line or in the corner of a busy office.

Rittal is a pioneer in the market of Rack cooling so take advantage of our expertise and contact us on cooling@rittal.co.uk or visit the link below…

SMP 1 - LCP Hero Image

 

#Rittal #LCP #IT #itinfrastructure #Edge #climatecontrol #cooling

 

https://www.rittal.com/uk-en/product/list.action?categoryPath=/PG0001/PG0800ITINFRA1/PGR1951ITINFRA1/PG1023ITINFRA1

SYSTEM PERFECTION

Digital transformation is rapidly changing the world. And that fits in with our guiding principle: “Nothing may remain the way it is!” Even if it might seem perfect, it can still be made better. Curious? Check out our video to learn more!

Watch here —> https://www.youtube.com/watch?v=a_pqh6JhwrU

 

If you would like more information then please do not hesitate to contact Rittal

W. Rittal Web

T. 01709 704000

E. information@rittal.co.uk 

#VX25 #System Perfection #Rittal

“Inline” configuration

For customers utilising aisle containment, our Liquid Cooling Package are available with an “Inline” configuration. This delivers the air directly into the cold area, for it to be utilised by your IT equipment.

These variants are available up-to a maximum output of 55kW per unit. This means you can build redundancy into your install by combining multiple units, which will work together to maintain the protective environment and increase their output in the event of an issue.

For more information, contact cooling@rittal.co.uk or visit the link below…

SMP 7 - Inline LCP

https://www.rittal.com/uk-en/product/list.action?categoryPath=/PG0001/PG0800ITINFRA1/PGR1951ITINFRA1/PG1023ITINFRA1

#Rittal #LCP #IT #itinfrastructure #Edge #climatecontrol #cooling

Reducing energy usage

In the current climate, reducing energy usage is a paramount concern to many IT professionals.

Rittal’s Liquid Cooling Package range are load following and utilise EC fan technology, meaning they will perform to the current output level that is required within the rack, rather than using excessive energy.

This increases the overall efficiency of your cooling system and reduces your energy costs.

For more information, contact cooling@rittal.co.uk or visit the link below…

#Rittal #LCP #IT #itinfrastructure #Edge #climatecontrol  #cooling

fri180426610

 

https://www.rittal.com/uk-en/product/list.action?categoryPath=/PG0001/PG0800ITINFRA1/PGR1951ITINFRA1/PG1023ITINFRA1

Rittal’s Liquid Cooling Package

Whether you have a small “office” rack, or you are implementing some high density computing project with large heat loads, Rittal’s Liquid Cooling Package can handle it.

We offer our LCP’s as standard at varying outputs up-to 55kW per unit. That means you can be more efficient with your equipment by filling up your racks.

All while having the peace of mind that your expensive equipment will be maintained within an optimum operating environment.

For more information, contact cooling@rittal.co.uk or visit the link below…

SMP 1 - LCP Hero Image

https://www.rittal.com/uk-en/product/list.action?categoryPath=/PG0001/PG0800ITINFRA1/PGR1951ITINFRA1/PG1023ITINFRA1