The structure of an electrical control panel is a combination of an enclosure and a back panel, similar to a breaker box in a home or office.
The enclosure is a metal box which varies in size and is typically made of aluminum or stainless steel. The number of doors (usually one or two) needed on the enclosure determines its size in most industrial applications. The enclosure will come with a UL safety rating (508A is typical) an IP rating, and/or a NEMA classification. These listings help users determine properties such as:
Indoor/outdoor use
Waterproof/water resistance
Dust/solid contaminants proofing
Hazardous conditions rating
Explosion-proof rating
These various classifications should be printed on a metal plate and attached to the enclosure for easy identification and reference.
A back panel is a metal sheet mounted inside the enclosure that provides structural support for DIN rail mounting and wiring ducts. DIN metal rails feature standardized dimensions and provide a mounting structure for electrical devices. Assembly Wiring ducts provide for the routing and organization of wires while also assisting in the control of electrical noise between devices inside the box.
Eight types of electrical components exist within an used electrical panel enclosure which define and organize the several different functions carried out by the panel. These components include:
Main circuit breaker. This is like the disconnect of the main electrical panel leading into a home or office. Miniature circuit breakers handle between 120V–480V in most industrial applications which established control over circuit components.
Surge arresters. This component prevents lightning strikes or utility power surges from damaging the electrical components inside the panel due to overvoltage.
Transformers. Depending on the incoming voltage, transformers may reduce voltage to 120V for various components or step down voltage to 24V in instances where incoming power is 120V.
Terminal blocks. These blocks help to organize and distribute the array of wires coming from various sources to different electrical devices.
Programmable Logic Controller (PLC). This is essentially a CPU contained inside the control panel. This unit is the brains of the control panel, providing monitoring and control of the various mechanical processes. In will include various inputs and outputs to and from mechanized functions of the production equipment.
Relays and contactors. These on/off switches control mechanized functions based on commands from the PLC. Smaller relays control functions like lights and fans. Larger relays, called contacts, control more advanced functions like motor controllers.
Network switches. The communication hub of the control panel, network switches facilitate communication between the PLC and the various network compatible devices on the production line.
Human Machine Interface (HMI). These components allow an operator to monitor or control certain functions of the machinery. Common HMIs include video monitors, joysticks, buttons, switches, and keyboards.
The design of a custom electrical control panel will depend upon the complexity of the system it operates. Designs can include a simple electrical relay system or a more complex PLC system with single or multiple PLC networks with IIoT or SCADA integrations. Indicators that your organization might need a custom panel design include a need for more advanced operation of various production operations; more cohesive, universal control of systems; and/or a need for improved HMI.
Maintenance is another key consideration for electrical control panels. Facilitating maintenance is a critical element in custom electrical control panel design. Maintenance elements should include:
Clearly labeled components, wiring, and terminals
Capability to monitor the status of the various electrical connections
Control of particulates and dust within the enclosure
Pest control measures
Electrical control panels are essential for industrial automation. They provide higher-level monitoring and control of the various functions of production machinery, allowing manufacturers to define, organize, and meet production objectives.
IndustLabs has more than 15 years of experience in the design and construction of electrical control panels serving industries such as:
Food & beverage
Oil & gas
Pharmaceutical
Power generation & power circuit components
Control Board Component
Manufacturing
Fluid handling
Material handling
We provide new installations and upgrades to existing systems. Contact us for more information concerning the electrical control panel solutions provided by IndustLabs.
Control Panels are a vital component of many industrial and commercial systems, as they allow operators to monitor and control various aspects of the system’s operation. They can take many forms, ranging from simple mechanical switches to advanced digital interfaces. They are used in a wide range of applications such as manufacturing, energy production, and transportation.
One of the key benefits of control panels is that they provide a centralized location for operators to monitor and control multiple aspects of a system. This can greatly increase efficiency, as operators do not need to physically move to different parts of the system to make adjustments or check status. Additionally, control panels can be programmed to perform certain actions automatically, such as shutting down a system in the event of an emergency, which can help to prevent damage or injury.
Another important benefit of control panels is that they can be customized to meet the specific needs of a given system. For example, a control panel for a manufacturing facility might include controls for temperature, humidity, and other environmental conditions, while a control panel for an energy production facility might include controls for fuel flow, power output, and other parameters. This allows operators to easily access the information and controls they need to effectively manage the system.
Control panels can also improve safety by providing clear and concise information about the system’s status and any potential hazards. This can help operators to quickly identify and respond to any issues, such as a power outage or a mechanical failure.
In conclusion, control panels are an important component of many industrial and commercial systems, providing operators with a centralized location to monitor and control multiple aspects of the system’s operation. They offer many benefits, including increased efficiency, improved safety, and the ability to be customized to meet specific needs. As technology continues to advance, control panels are becoming more advanced, allowing for more sophisticated monitoring and control capabilities, and increasing the efficiency, safety and ease of use of the system they are controlling.
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