Cable assembly - integrated and automated

Cable assembly for control cabinet manufacturing is "small-scale work" and performed in very small batch sizes. How this can be automated and what benefits automation brings have been put to a practical test by Elektronik Schwab GmbH in Krakow am See. Offers are now being generated automatically and a state-of-the-art machine park undertakes tasks such as assembly, cutting, stripping, crimping, tinning and direct labelling. Data consistency is provided by the EPLAN Platform, in particular the modules for wiring and 3D control cabinet design. 

If you are you looking for "hotspots" in control cabinet manufacturing and cable assembly according to Industry 4.0 principles, the search is unlikely to begin in Germany’s Mecklenburg lake region. But a principle of digitised production is the ability to develop state-of-the-art manufacturing approaches beyond core industrial regions. This has been proven by Elektronik-Schwab GmbH in Krakow am See, some 70 km east of Schwerin. Founded in 1996, the company began manufacturing printed circuit boards for customers, then gradually expanded its activities and is now regarded as a specialist in cable assembly and control cabinet manufacturing.

In both business segments, the company, which currently employs 68 people, works for customers mostly from high-tech industries such as medical technology, the automotive industry, wind energy technology and food equipment.

Control cabinet manufacturing: Small series production and high expectations

The control cabinet manufacturing department recently moved into new production premises. Head of Sales Reiko Schmecht: “We usually manufacture smaller series of control cabinets for customers. Customers either provide us with EPLAN data or we prepare the data using EPLAN Pro Panel. This enables consistent standards of quality in the manufacturing of the cabinets”.

Another benefit of working with EPLAN Pro Panel is that the detailed control functions in 3D cabinet design avoid modifications being required later. A control cabinet is manufactured exactly according to plan. Christian Schwass, Head of Design and Control Cabinet Manufacturing: “Highly precise design saves us time and enables us to deploy our employees effectively. The labelled cables give fitters precise instructions on wiring so that for many tasks we can use non-specialist personnel. The specialist personnel are then available for other tasks".

Fully automated production of sets of wires

The sets of wires for control cabinet manufacture are optimally labelled and 100% tested. Reiko Schmecht: “We have many external customers in this business area and have invested heavily in automation in recent years”. The results clearly evident as you walk through the production hall. A Komax Zeta system assembles cables fully automatically, switching between 36 cable types and six types of wire terminals. Other systems undertake tasks – also fully automatically – such as cutting, stripping, crimping, tinning, and labelling of the cables.

Balanced "mix" of manual and automated tasks

This service is in demand, especially as Schwab offers numerous specialisms. For example, the processing of miniature cables down to 36-strand AWGs with a 0.02 cross-section. These cables are used in sensor applications and are 100% tested as are all other sets of wires. Manual workstations are also available in every area of activity, e.g. soldering and tinning, where specially trained employees perform the fine work. Special contacts, e.g. from the Harting portfolio, are also pressed at a consistently high standard of quality on semi-automatic machines.

Investments that pay off

In recent years Elektronik-Schwab has invested considerably in automated cable assembly and control cabinet wiring, and has been successful in fully utilising the basic capacity of the new machinery. Reiko Schmecht: “The machinery needs to operate at least in a two-shift cycle, and this is what they are doing”. This indicates the level of demand in the industry for automated external cable assembly – provided the price is right and an appropriate communication and automation platform is available. Automation ensures the right price, and the appropriate platform is provided by EPLAN, which is deeply rooted in procedures at Elektronik-Schwab.

Consistent data – from inquiry and costing through to the machine itself

Data consistency already begins at the inquiry stage. Reiko Schmecht: "Our homepage provides an Excel list which can be used as an enquiry form for wire-strand production”. Schwab automatically generates an offer from the Excel list, based on parts prices taken from an ERP system as well as on quantities, production time, testing, packaging and dispatch. When an order is placed, the project data is converted into an EPLAN macro which can be used directly by the fully and semi-automated machines and which contains all cable-related data such as colour, cross-sections and labelling. These macros are then processed by Komax machines.

Cable Assembly 4.0: One network for all machines

Such a workflow positions Schwab perfectly for wiring control cabinets. The company is then able to complete their own projects profitability, while also being competitive as an external service provider. This is all based on integrated utilisation of the EPLAN Platform and the Wiring and EPLAN Pro Panel modules, as well as their connection to an ERP system and – most importantly – to systems for automated cable assembly.

The advantages of such a systematic approach based on EPLAN data are easy to quantify. Reiko Schmecht: “Savings of 50 to 60% in wiring effort are realistic – even up to 80% when taking into account pre-assembly”. But this requires customers to be willing to disclose the necessary data: “There are still reservations. But many of our customers are planning to use EPLAN and especially Pro Panel. We are happy to support them because it offers enormous potential for rationalisation which they can tap into”.