Guiding LightMachine directive: A practical translation into engineering

Dear Reader:

The clock is ticking. The best opportunities await only for those companies that work on streamlining their engineer-ing processes with a singular focus on productivity. We can help you do that. Our Professional Services Team is ready to go: In the starting blocks for process analyses, ROI evaluations all the way to the implementation of the new EC machine directive.

Find out where you can cut costs. In conjunction with the machine directive, our Engineering Performance Factor not only clearly shows you the status of your current productivity level, but it also reveals substantial savings potential. See it in writing, live and free of charge, at the Hanover Fair 2010 (Hall 17 / Booth D40).

Will you be there? Expect shorter processes – count on EPLAN.

Hans HässigManaging DirectorHans HässigManaging Director

eplanet special

The road your machine must take to the European domestic market, from design to hazard analysis to properly standardized EC compliant documentation.

Priority 1:The new Machine Directive 2006/42/EC was enacted at the end of 2009. EPLAN developed a specifi c training and consulting package cover-ing the specifi c requirements of practical engineering. It is compact, clearly arranged and precise. Learn to deal with the maze of new legal requirements that demand a clear view. After all, who is able to size up the entire jungle of amendments and legal requirements of Ma-chine Directive 2006/42/EC and its effects on the engineer-ing process? Ultimately, the new machine directive demands a signifi cant expansion of docu-mentation with a defi ned struc-ture and documentation must be archived for at least ten years. You’ll be glad to know that EPLAN products support

the proper standards for project planning at its best. Specifi cally, EPLAN Software & Service has fi ltered out and clearly defi ned the most important elements of the machine directive. This spe-cially developed training and educational consulting concept gives you what you need to comply with the new rules, and the ability to prevent safety and warranty problems. At the same time, after the machine directive has been implemented, the en-gineering process can be stand-ardized – and that generates long-term productivity.

Specifi c training programsWhich compliance standards must a manufacturer of entire systems or partial systems such as enclosures meet? How should enclosures be planned from a mechatronic perspective under

current standards? The nuts and bolts of these and other ques-tions about CE marks, conformity evaluation processes or health and safety protection require-ments are explained in focused seminars. The topics range from implementing the machine direc-tive to project planning using the proper standards, all the way to risk evaluation.

Advice is includedEven special training for CE documentation administrators is part of the program – exactly tailored to the engineering re-quirements. That is why compa-nies also receive practical help on location. EPLAN consultants coach machine builders and sys-tems providers to ensure that the implementation of the new ma-chine directive complies with the law. In the “Check-up,” control

documents are analyzed and specifi c change recommenda-tions and actions are defi ned. Machine builders who must ret-rofi t existing systems to comply with the new standards receive active support. Even a risk analy-sis/CE conformity declaration of machines and systems is offered. Finally, the practical implemen-tation of Machine Directive 2006/42/EG provides legal security, because the machines are built and tested in compli-ance with the law. The entire life cycle of the system is supported beginning with the continuous design system required. It starts with the order, progresses to de-sign, project planning and com-missioning. It even includes main-tenance. These well-structured, effi cient engineering processes give companies a competitive productivity advantage.

IEC 61346

EN 61355

ISO 14617

ISO 13849

IEC 61508

2006/42/EG

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Audi accelerates: EEC speeds up workfl ow Check IT out: EPFplus and Check-ups Competence: Rittal systems solutions EPLAN: Now in Antarctica

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Sophisticated and successful:Pilot project for the Audi TTChassis must be developed, built and placed into operation in a short time. Audi tool makers rely on functional engineering and have realized signifi cant savings thanks to EPLAN Engineering Center (EEC).After Audi had implemented the fi rst system as a pilot project for the Audi TT in 2005, other sys-tems followed for the Audi A4, A5 and currently, door systems for the new Audi A1.The interme-diate result is impressive. To date, Audi has installed several hun-dred robots and many PLCs using EPLAN Engineering Center.

Designing, planning and programming in parallelThe basic idea of functional en-gineering is simple. Processes that run in parallel increase over-all effi ciency and effectiveness. Companies that have developed a mechatronic construction kit for hardware, software and pneu-matics based on corresponding standards at the beginning of the project, can run design in paral-lel.

The construction kit model saves time and avoids errorsThese are the reasons why con-struction kits with the related pneumatic and electrical sche-matics, as well as the control software for mechatronic compo-nents are confi gured and stored in the construction kit. The system can be planned using standard-ized modules. The modules are then individually parameterized for their respective specifi cation – in the case of a robot grip-

per, perhaps by the number of respective shunts or by the valve grouping. Using this functional project planning, all objects (ro-bots, shunt circuits, control devic-es) and their parameters such as device identifi ers can be speci-

fi ed in a mechatronic model. The EEC automatically generates the corresponding design docu-ments, including electrical sche-matics, PLC programming and pneumatic plans, and ensures their consistency.

Decisive factor in time to market“Today, we are able to gener-ate our schematics for EPLAN Electric P8 entirely with EEC,” says Sebastian Lerch, designer.

In the beginning, of course, es-tablishing a library element and generating the required calcula-tion formula took a little longer compared to a manual design of the individual components. But after the building blocks library

has been established, the time saved is enormous. Predefi ned standard modules are always kept current centrally and can be retrieved automatically for recur-ring functions and modules.Design manager Reinhardt Mielke is pleased that automatically run routine, repetitive steps free up the engineers to utilize more of their time developing innova-tive product solutions, stating “The project specifi cations and guidelines from previous plan-ning processes ensure continu-ity of the specifi cations across disciplines in a mechatronic construction kit.” Helmut König, head of planning and automa-tion technology adds, “The EEC rules ensure compliance so that our specifi cations are implemented 1:1 in the design documents of our suppliers.” This continuous optimization of the engineering processes has given Audi a decisive lead in the time to market.

Flexibility protects the investmentShortly after the EEC had been introduced, Audi decided that it

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Audi acceleratesEPLAN Engineering Center (EEC) is Audi’s key to shortened engineering cycles

Today, the automotive world is driven by a marketplace that de-

mands rapid change. New technologies and new de-signs proliferate, and a con-tinually increasing number of new models enter the market at shorter and short-er intervals. There is no alternative; system builders for chassis must keep pace. Another factor is added by the technologies used for car body construction, which are developing at a rapid rate. But here too, Audi has proven its leader-ship thanks to the EPLAN technology. By employing functional engineering with EPLAN Engineering Center, this trendsetter has main-tained its independence from parts suppliers.

Wilhelm Hacker, PLC programmer

“EEC helped us to signifi cantly reduce our time commitment

to the project planning of PLC controls.”

would use the PLC controls made by Phoenix Contact and the as-sociated PCWorx programming software for the chassis design lines of the new Audi A4. “Dur-ing the restructuring of the con-struction kit to Phoenix controls it was confi rmed that we had made the right move by relying on EPLAN Engineering Center,” reports Anton Habermeier, head of systems and device construc-tion. Within a few weeks, the new PLC programming software was integrated and provided im-pressive evidence for the open-ness and fl exibility of the system.“With the EEC, we were able to signifi cantly reduce the time commitment for project planning of the PLC controls,” reports Wil-helm Hacker, PLC programmer. “It was possible to generate the basic PLC project and the operat-ing interface of the controls en-tirely automatically.” But the most important advantage was that the investment that had already been made in the mechatronic construction kit related to Audi-specifi c rules, remained intact and could also be expanded continuously.

simulation in Focus“Fluidtronic”: Mechatronics allows virtual commissioning

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Mechatronics is pure inspiration. It unifi es different disciplines such as hydrau-lics, pneumatics, electrical engineering, mechanical engineering, informatics or control technology. The mechatronic approach is undisputedly innova-

tive. This has already been proven in engineering and is refl ected in the effi ciency and functionality of the overall system. Usually, a project does not realize the benefi ts by being supported with mechatronical based simulation software until experience-based design no longer suffi ces, or unless malfunctions disrupt operations. Today, fl uid-power simulation tools are still a niche, but this is set to change. The “Fluidtronic” research project is working at adapting the development environment by using the example of EPLAN Fluid and DSHplus. The target is a PLM solution that combines information islands and various data fl ows into a consistent solution.

“Fluidtronic”: Designing, simulating, optimizingWhy would a consortium con-sisting of nine companies and two research institutes that are supported by the German Fed-eral Ministry of Education and Research work on “Fluidtronic”? The answer is simple. Complete integration of fl uid-power simu-lation tools would considerably facilitate the understanding of the overall system in the early phases of development. Addi-tionally, onsite commissioning is increasingly time-consuming and costly in the absence of vir-tual testing.

When EPLAN Fluid and DSH-plus are used, engineering meets simulation The research group used so-lutions from two market lead-ers to integrate design and documentation when develop-ing new systems. These were EPLAN Fluid for fluid-power engineering with automated documentation, and DSHplus, a simulation program for hy-draulic systems.

Coupling of documentation and simulation is a decisive advantageThe expert team consisting of several members quickly agreed that a major objective on the path from design to commission-ing was the successful coupling of documentation and simula-tion. In the solution, the circuits

are designed in EPLAN Fluid and simulated in DSHplus. The results of the dynamic system simula-tion, including important system and environmental parameters of the system, have been made available in an HTML report. This report can in turn be linked dynamically with the schematics. Thus, the plant documentation is

completed consistently, and de-sign reports are accurately pro-vided to customers. As DSHplus has interfaces for a coupled PLC simulation or hardware-in-the-loop simulation, the consistent engineering concept can be ex-tended by virtually commission-ing the plant with a real control device later on.

Feasibility analysis to support customer requirementsHow can an initial simulation of interacting individual param-eters be achieved? By entering all recorded and calculated parameters and then feeding the corresponding simulation model with the system structure and component data from the

schematics. The feasibility of the requirements using several re-sults diagrams is displayed. This also prevents the sales depart-ment from making promises to the customer that can later result in enormous additional effort in the design of the plant and the machine.

Virtual commissioning saves time and moneyThe detailed virtual plant model can be used in additional devel-opment processes, so that virtual plant commissioning can be done in the run-up stage. Software-in-the-loop interfaces (SiL interfac-es through OPC interfacing) can be used to couple the real PLC software to the simulation model. Thus, the machine control unit no longer communicates with the real plant, but receives its input variables from the virtual plant

model and controls them with the calculated output variables. The threat of damage to the real plant is averted.

Adaptation strategies before actual commissioningThe aim of this coupling is not only to test the PLC software in the simulation, but also, if neces-sary, to develop it further and to ensure transferability of the results to the implemented drive. Adaptation strategies for poten-tial system changes can already be tested. If necessary, these can be adapted long before the real commissioning of the fl uid-power system. This virtual design of the machine control system can also be used to develop and analyze new control and design strate-gies with minimum time.

www.fl uidtronic.de

Testing. Adapting. Improving. Adaptation strategies can be developed long before real commissioning of the

fl uid-power system.

The consistent use of simulations allows potentially weak points of the

system to be recognized and eliminated at a very early point in the

development process.

Automatic derivation of simulation model

Iterative adaptation and detailing of confi guration

using the simulation results

Set-up procedure for press using project planning template

Obtain quality certifi cation of confi guration fromhydraulic simulation

Dürr Ecoclean cus-tomers have one thing in common:

They need clean solutions for clean components. This renowned worldwide manufacturer of parts cleaning systems for auto-motive production worked closely with Motorblock, Zylinderkopf & Co. to ensure clear solutions; it also structured its engi-neering fl awlessly. Using the EPLAN Platform, Dürr Ecoclean maintains data continuity in development and design. The EPLAN platform ensures a consist-ent exchange of data with all systems.

Clean affairEPLAN Platform – Process design with continuity

Deburring, spray cleaning,injection fl ood washing, dryingThe product spectrum of Dürr Ecoclean GmbH in Monschau ranges from small serial devic-es for industrial cleaning up to more complex, sometimes robot-supported systems. In EcoCFlex, a six-axis robot that is positioned at the center of the system man-ages the parts handling and guides the components to the various work stations, such as deburring, high-pressure water beam, spray cleaning, injection

fl ood washing and drying. This ensures high fl exibility and ad-aptation to different work piece geometries. Beyond that, Dürr Ecoclean produces systems for processing cooling lubricant, and for linking production proc-esses in metal processing.

A uniform perspective across all tradesDürr Ecoclean operates under the philosophy of keeping the entire process in view. Naturally, this applies to engineering as well. In 2008, Dürr Ecoclean replaced the software it previously used for process and fl uid engineer-ing and migrated to the EPLAN Platform. Now, electrical design, fl uid design and instrumentation and control (I&C) engineering work together in an integrated way, using the same database

and data. Each discipline’s work is transparent to the other dis-ciplines. Dürr Ecoclean seized the opportunity to signifi cantly improve its effi ciency by integrat-ing engineering processes. In July 2008, electrical engineers migrated from the old EPLAN 5

to EPLAN Electric P8, EPLAN’s new generation electrical engi-neering package. The switch to EPLAN Fluid and EPLAN PPE fol-lowed. The latter is mainly used to generate P&I diagrams.

With deep integration, engi-neering inconsistencies are completely avoidedIn collaboration with EPLAN Software & Service, the PPE module was confi gured to make the user interface identical to that of the former system. Now, electrical engineers, and proc-ess engineers can work with the PPE module. This provides more workfl ow fl exibility. Changes made by electrical engineers are automatically placed in the fl ow diagram. In EPLAN PPE, modules were defi ned for functional as-semblies such as fi lters and vacu-

um dryers. To a large extent, the EPLAN library is used, and it is an excellent base, because the other EPLAN systems also access this library.

Organizational alignment promotes a more effi cient workfl owDürr Ecoclean was well aware that merely adopting a common CAE platform would not capture all of the advantages of integra-tion. Changes would also have to be made at the personnel and organizational level. To accom-plish this, process and fl uid en-gineering design that had previ-ously been a part of mechanical engineering was merged with the electrical design group. Elec-trical designers were trained in EPLAN PPE. This helped to elimi-nate bottlenecks that were previ-

ously unavoidable due to only one designer being available to create the P&I diagrams. Now, anyone in the electrical design group can help out. All three disciplines share the same data in real time, including modules stored in their common EPLAN database, with major gains in ef-fi ciency and accuracy.

More integration, step by stepIn addition, plans are in place for connecting the EPLAN data-base to the company’s business system. This will start with the transfer of component require-ments from EPLAN to SAP. In a subsequent phase, a designer working in EPLAN will specify the need for a component and SAP will allocate or order the component.

Changes made by electrical engineers are automatically located

in the fl ow diagram.

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Engineers from EI&C, fl uid engineers and electrical engineers working

with the EPLAN Platform.

Deburring, high-pressure water jets, injection fl ood washing and drying –

each one of these functions is handled by the fl exible part handling in EcoCFlex.

Automating enclosure designstandardization is the catalyst to integrative workfl ow

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Where are the parallels between logistics and engineering? The answer is simple. In logistics, some things must be at the right place at the right time. This also applies to the data in engineering. The experts at Lödige

Fördertechnik GmbH in Warburg are specialists in both disciplines. They structured their engineering processes across trades with a goal of greater standardization. This was achieved by using EPLAN Electric P8 and EPLAN Cabinet. In enclosure design alone, 20 percent savings were realized using a uniform database across the entire development and production process.

Making heavy lifting lighterLödige Machine division in War-burg, Germany, builds various types of load-lifting equipment, such as scissor lifts, stacker cranes and cargo-lifting systems for warehousing and logistics. These even include vertical car parks and elevators to make buildings accessible to wheel-chairs. The company’s designers work on many simple projects, es-pecially for the air freight and lo-gistics applications. At the same time, they also handle complex projects that include hundreds of machines, which operate as one integrated system. Many of these machines are custom-designed.

Costs and time pressure necessitate modularizationEngineer Burkhard Pöhler, head of electrical design, has made it his goal to expedite the modu-larization of machines and sys-tems. “Approximately 25% of the machines we produce are standard machines and 75% are custom designs. Over the medium term, this will turn the other way around. Cost pres-sures and the sheer scope of in-dividual projects demand it. One of our current air freight system projects includes approximately

1,000 individual machines.”

Multiple disciplines share a common data platformAt Lödige Machine, a uniform data and user interface platform is important. In electrical design, the company was an early adop-ter of EPLAN Electric P8, which ushered in the era of the EPLAN Platform that supports EPLAN products for multiple engineer-ing disciplines. “The principle of

a uniform database for various disciplines convinced us immedi-ately,” says Burkhard Pöhler. “It offers considerable advantages in quality and speed, especially in complex projects.”

Software tool generates schematics automaticallyFor larger projects, the electri-cal designers can create 50-100 projects, each one containing as many as 500-600 schematic

pages. The EPLAN Schematic Generator module vastly acceler-ates this process. In the case of the AS-i modules, which are used by Lödige, primarily for sensor control, the software shows de-signers the free addresses and can automatically set location desig-nations. For address assignments, designers use a tool that gener-ates a tabular PLC card overview. Setting location designations auto-matically makes assignments eas-

ier. All references, as well as the assignment of main and auxiliary elements remain consistent, even when changes are made. This saves time and prevents errors.

Web-based component data import tool saves time, ensures accuracyLödige designers either create the 3D view of individual com-ponents, or import them from the EPLAN Data Portal. “We prefer

“The principle of a uniform base of data for various disciplines was

immediately convincing.“Burkhard Pöhler, head of electrical design

suppliers from whom we can di-rectly import data, including con-nection points, from the portal directly into a project,” says Burk-hard Pöhler. The EPLAN Data Portal also provides other advan-tages for Lödige, because exten-sive data can be sent to panel builders in conjunction with the re-quest for a proposal. In addition to the bill of materials and other information, panel builders also receive cable overviews, terminal diagrams and fi les for labeling.

3D views prove instrumental in preventing build delaysWhen an enclosure is to be de-signed, EPLAN Cabinet comes into play. Cable ducts, mounting rails, terminals and contactors

are simply positioned at the click of a mouse. The result is a virtual prototype. It meets all require-ments of a CAD illustration and can be implemented 1:1 into the mechanical and electrical design. This means project plan-ning accuracy from beginning to end. “We profi t not only from standardized enclosure layouts, but we also receive additional data such as wire length and drilling data for the 3D design, practically free of charge. And the many automatic functions we wrote as scripts speed up our work considerably,” reports a pleased Burkhard Pöhler. Hard facts support this success. Lödige has achieved savings of over 20% in enclosure production.

Effi ciency gained by Platform functions

Is all of the potential of the EPLANPlatform consistently used to in-crease effi ciency? Are project plans and working methods stra-tegically coordinated with each other? With a full knowledge of the functions and targeted ad-justments in the workfl ow, up to 90 percent of savings potential can become accessible.

Machine directive documentation

This Check-up reviews conformity with Machine Directive 2006/42/EC, and the degree of compliance of the documentation. It is the ini-tial guideline for consultants who fi rst review the control documents for completeness and proper use of standards. A qualitative evalua-tion of project planning data and the progression of a project plan in hardware construction are also performed.

Check up system

Check updocumentation

Check iT outTangible concepts to raise productivity

The most important questions that surface due to cost pressures relate to productivity and transpar-ency. How does your company measure up? Get

eye-opening answers from the Engineering Performance Factor (EPF) – a Quick-Check from EPLAN that is free of charge. Our experience has consistently shown that sub-stantial opportunities for optimization can be found even

in seemingly well-structured development processes. To retrieve this hidden treasure, EPLAN has developed check-up days. On those days, consultants analyze individual company processes by using realistic cost and utilization evaluations that support robust investment decisions. Tan-gible concepts for more effi cient processes emerge, which make the future more productive at lower costs.

EPF is an engineering design process checkThe issues are the same eve-rywhere. Companies must ur-gently put their productivity to the test. A ‘short process’ or op-timal workfl ow from engineer-ing to production is the ultimate goal. But the key issue is: In reality, how far removed is the company from this continuity, and which savings potentials are not utilized? To fi nd out, EPLAN Soft-ware & Service has developed an En-gineering Perform-ance Factor (EPF). This engineering-check determines the strengths and weaknesses in the continuous proc-ess. It shows the rank of product de-velopment compared to prior art. Customers who are interested in pursuing this option re-ceive an individual evalua-tion including a short analysis and tips for specifi c courses of action. And all of this is free of charge.

What happens during a Quick-Check?A questionnaire sheds light on all phases of the engineering proc-ess such as electrical design, en-closure production, mechanical design, production integration

and data retention. Each of the 12 questions has four potential answers that repre-sent a cer-t a i n

lev -el of development in the respective phase. Based on the number of points achieved, the deviation from the optimal process can be seen. In this process, the customer assigns the relative weighting.

If, for example, enclosure pro-duction is of little or no signifi -

cance to the com-pany, the

related

question receives a

low weighting factor. In this way, the number of points obtained by the ques-tionnaire is tailored to the in-dividual requirements of the company.

Turn weaknesses into strengths,make cost savings tangibleIf the engineering-check has re-sulted in potential opportunities in the process, EPLAN works on optimization. A select team of specialists has tailored the check-up days to the EPF concept,

which progresses as follows: In a one- to four-day Check-up,

a consultant analyzes the processes in the company

and develops individual optimization concepts. All opportunities with the potential of rais-ing effi ciency are put on the table.The experience of EPLAN consult-ants has shown that savings po-tentials of 50,000 to 300,000 Euros

are defi nitely attain-able. Often, these

result from seemingly insignifi cant improve-

ments such as an optimal connection of parts/parts

lists with business systems. Or also simply by standardiz-

ing documentation that is used repeatedly. Alternatively, a change of engineering method, or an optimized data transfer between disciplines is often the key to success.

How does the Check-up work on location?The EPLAN consultant, the de-cision-maker and the key user

discuss the typical course of a project around a table.All phases of the process are evaluated in detail. Hardware, IT infrastructure, systems struc-tures and working methods are also scrutinized. Subsequently, the Check-up team determines the required time and effort with associated costs and establishes corresponding workfl ow plans.

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There are opportunities in the overall process

At the center of the Check-up in engineering is the focus on engi-neering from the process perspec-tive. This is very close to actual practice, because the inclusion of the working steps and the time distribution over the course of the project are based on an example of a typical project. The potential for time and cost sav-ings resulting from an optimized engineering workfl ow can be as much as 50 to 90 percent.

Opportunity for standardization

From the start, opportunities for standardization offer up to 30 percent higher effi ciencies to those who migrate to EPLAN. This pays for the migration to EPLAN Electric P8 and the EPLAN Plat-form right away. This is due to the optimized system data. And project handling raises the pro-ductivity, user skills and work methods to a new level.

Working methods on the test bed

There is a simple and sound so-lution for working on parallel processes with a consistent and common database for all trades. It is EPLAN Engineering Center (EEC). This check-up method re-veals up to 80 percent of savings potential in design. It is the result of thinking mechatronically and designing modularly, from me-chanical to electrical engineer-ing, fl uid power to visualization and all the way to production.

Check up Engineering

Check up Migration

Check up Method

The key aspects and weighting of the individual process steps, as well as the short-term, medium-

term and long-term goals are mu-tually defi ned. After that, EPLAN creates a report of the analysis

A productivity check-up, a process analysis, an engineering opti-mization – these processes lower costs dramatically. EPF and the

check-up days highlight areas where improvements can be made.

with a specifi c action plan and profi tability aspects.In a return on investment analysis

the savings potential is clearly shown in terms of costs and ben-efi ts. It gives companies individ-ual optimization concepts that can be achieved with EPLAN in each phase.

Act now! “Check IT out!”The consultants from the profes-sional services team have a keen

eye for detail. They have accumu-lated many years of experience while working on many customer projects in various sectors. They know what really matters. And they pass their experience on, so that cost savings potential will be realized. The range of services varies and is always geared to the individual challenges of the company.

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practice, because the inclusion of the working steps and the time distribution over the course of the project are based on an example of a typical project. The potential for time and cost sav-ings resulting from an optimized engineering workfl ow can be as much as 50 to 90 percent.

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Fully interlinkedEnclosure production is a process that crosses disciplines from engineering to commissioning

Enclosure production is always associated with the quest for

reducing costs across the entire product develop-ment process. How can this be done when mar-gins are narrowing and competition is intensify-ing? The answer can be found in the interlinking of engineering, production and commissioning across disciplines. Engineering data must be passed on, specifi cally, from begin-ning to end starting with project planning up to installation, and it must be used uniformly. The virtual prototype replaces what used to be very expensive physical model design.

Successful start with EPLAN Electric P8Enclosure production starts with the schematics designed easily by EPLAN. The E-CAE system automatically generates corre-sponding device, terminal and wiring lists. These documents provide detailed information about components, connec-tions or gauges, and they can be transferred to downstream processes. The next step, which sometimes also runs parallel, is the panel layout. Using the elec-trical documentation as a base and including the data that is available from manufacturers, the housing with all accessories is confi gured in EPLAN Cabinet as a 3D prototype.

EPLAN Cabinet creates systematic orderThe enclosure can be equipped virtually, using devices originat-ing in Electric P8. Complete arti-cle data such as enclosures and fi xed devices are imported from the EPLAN Data Portal or select-ed by product confi gurators. In the enclosure, the user suitably places the component without any problems because EPLAN Cabinet automatically considers the relevant minimum distances and locked areas. Moreover, its automatic collision check fea-ture ensures that the enclosure door always closes.

The new prototype is virtual, not physicalUsing the 3D model, enclosures can easily be dimensioned, built and tested, long before they are produced. This ensures error-free design data, precise plan-

ning and a quicker progression of the projects. Companies in enclosure production profi t sig-nifi cantly from this deep inte-gration with production, as the required data for the mechani-cal production of mounting pan-els or enclosure parts can be retrieved directly from the 3D prototype. Information about cut-outs, as well as holes and threads are transferred from the 3D model and fed directly into the processing centers by cor-responding NC interfaces. Even optimized cutting lists for NC-supported trimming techniques can easily be generated from the 3D data. They ensure ac-curately fi tting cable ducts and mounting rails.

Full function with integrated 3D routingBeyond that, all advantages of automatic wire packaging ap-ply. Integrated 3D routing deter-

mines the best possible routing-paths, and also the required conductor lengths within the enclosure. Whether bundled or handled at the end of the con-ductor – specifi c machine inter-

faces supply the data directly to the automated production. The completely packaged conduc-tors can then be installed in the enclosure. Manual work and

expensive documentation are history. Even the required wire labeling data is taken 1:1 from the electrical project. Specifi c wire lists exactly document the routed connections. This way,

devices are wired signifi cantly faster, because no interpretation of any kind is required.

Faster, leaner, more convenient and betterWith this integrated project planning approach, the entire product development process becomes faster, leaner and more convenient. Instead of preparing item lists in analog form and con-structing physical prototypes, en-gineering data from the electrical design are transferred directly to panel production. The result in-cludes fl awless production data, documentation without repetitive data entry, optimized production capacities and a focus on core competencies.

The integrated project planning method makes processes in enclosure

production faster, leaner, more convenient and better.

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„Rittal’s system is faster, better, worldwide” With

this slogan, Rittal intro-duced impressive system architecture from housing technology, fl ow division to system climatization all the way to IT, at the SPS/IPC/Drives 2009 trade fair. This proves Rittal’s competency as a provider of complex systems for the building services engi-neering and IT industries. Engineering tools that ensure effi cient planning processes play a key role.

The competence factorrittal systems solutions combine mechanical design, power, climate control and engineering from a single source

Intelligence from the construction kitBy using an intelligent construc-tion kit system of the infrastructure, Rittal ensures effi cient complete solutions for energy distribution, automation, building installation and IT. The backbone of the sys-tem architecture is the enclosure and the IT rack system platform

TS8 with its extensive acces-sory kit. Customers profi t from the advantages of the platform

concept such as high fl exibility, simple and quick installation, lit-tle warehousing, fast availability and high quality.

Convergence based on experienceRittal also presented the latest solutions for the man-machine interface. This also included the mounting arm system CP-C that is optimized for design and func-tion. This system platform sup-ports especially the increasing convergence of IT and automa-tion. On top of that, Rittal goes far beyond the mechanical solu-tions and offers, for example, suit-able power supply solutions and energy-effi cient air conditioning.

These include the USV system PMC 40, the type-approved switching system Ri4Power and

the new cooling device series Cool Effi ciency.

Parts integration straight from an electronic catalogIn addition to the optimal com-patibility of all components, efficient engineering also gen-erates substantial savings op-portunities in the planning proc-ess of machines and systems. This is made possible by the free of charge CAD data from the RiCAD 3D catalog for fast planning of the mechanical de-sign. In addition, software solu-tions such as Rittal Power En-gineering support the fast and safe design of current flow with a new version 4.1. Moreover,

Rittal Therm supports energy-ef-ficient dimensioning of cooling device technology.

Convincingly linked solutionsTo achieve a heightened overall view of the engineering proc-esses from the mechanical to the electrical engineering all the way to automation, Rittal has increasingly interlinked its formerly independent engineer-ing tools with EPLAN Cabinet and EPLAN Engineering Center into overall solutions. This way, various engineering data can be utilized in all phases of the product design and system de-sign with all the advantages of a continuous data concept. The clear advantages include short-ened turnaround times and re-duced costs.

Rittal system architecture offers concrete economic advantages in housing technology,

current fl ow, system climatization and IT.

10

One year after its launch, EPLAN Data Portal has had a substantial infl uence on engineer-ing. Over fi ve million downloads speak for

themselves. It supplies tens of thousands of up-to-date, web-based, verifi ed and certifi ed parts and de-vice data from many component manufacturers. That helps speed up the project. Now, the new version of the Data Portal is released with expanded function-ality. These accelerate the organization, search and administration of parts.

Time is moneyIn addition to perfect software support, users in engineering require component data that can be imported into the project 1:1. This is where the web-based EPLAN Data Portal comes into play. Within one year it has evolved into an indispensible da-tabase. Naturally, the data are ex-panded and new manufacturers are added on a continuous basis. The new version provides many exciting search and administrative functions that make project plan-

ning even faster, more productive and more comfortable.

Tried and testedFaster searching, easier han-dling, direct fi nding. Smart fi lters now allow the storage of all fi l-ter schemes as individual search patterns. Moreover, these can conveniently be retrieved again and again, saving substantial amount of time. Keywords can be tagged with corresponding catch words, parts are organ-ized perfectly by purpose of use,

by procurement or project name. Now, parts can be grouped and organized to provide an excel-lent overview.

Best connectionRelationships always play a role, even between parts. The new accessory management in-cludes a “jump function” which easily displays suitable auxilia-ry devices for the main devices that are selected. Of course, the same is true for the reverse. To facilitate smooth collaboration, work groups that design to-gether and use a uniform parts database can now be formed. A group administrator defi nes the fi lter and part selection so

that only those parts that are approved for the project can be selected. Another new feature is the messaging – for direct com-

munication between all project participants.

Searching made easyWith tens of thousands of parts and device data listings in the portal, one factor is always criti-cal: the speed of the search. A suitable component can be found in a fl ash by using direct search with a search term, or by conventionally searching by manufacturer, product group or in catalog view. Via the new tree structure display, manufac-

turers’ component data can be searched exactly as if it were in a catalog. No tedious paging, no manual transfer. Simply insert the data into the project and you are set to go.

Earlier is betterConsistent data is the linchpin of an effi cient product develop-ment process. The new macro preview in the EPLAN Data Portal shows the macros that are available for a respective device or part simply by click-ing – even before download-ing has been started. Complete macros from, for example, PLC devices, measuring transducers or frequency converters can be imported into the project. In-tegrated connection diagrams and function templates ensure exact representation of complex devices and components. This not only ensures a smooth inte-gration, but also saves the parts information on to your parts da-tabase for future use.

speed up the projectThe new version of EPLAN data Portal goes online

The new version provides many exciting search and administrative functions that

make project planning faster, more productive and more comfortable.

11

Engineering On The Last FrontierWith Antartica EPLAN expands footprint to all six continents

When the Belgian government commissioned the International Polar Foundation to build the fi rst zero emission climate research sta-

tion in Antarctica, EPLAN helped surmount many unique challenges. Built in the polar summer of 2007-08 on the Utsteinen nunatak in eastern Antarctica and named “Princess Elisabeth Antarctica,” this remarkable scientifi c outpost is powered entirely by renewable energy and has a minimal environmental footprint. For example, 80% of its water is recycled. Johan Berte, chief project leader, engaged Laborelec for system design and to identify the best hardware and technology. Detailed electrical drawings were produced by Pro-Engineering Design using the EPLAN software.

New dimension in power management“There is no electrical grid at the South Pole, so conventional circuits weren’t suitable,” states Laborelec’s chief engineer, Sven Kerremans. “We had to be pretty inventive. The energy supply is dy-

namic – wind and solar – creating an unstable network. Fortunately, Schneider Electric, our hardware partner/supplier, developed a control system for a smart grid that automatically directs supply to priority power demands via a Demand Power Management System. A world fi rst!”

Meeting high fl exibility requirementsThe size of the build-out was equally challenging. “Within a short time span we had to draw

up an installation consisting of 26 kilometers of cable, 29 control cabinets and 2,200 I/Os,” says Vincent Van den Broek at Pro-Engineering Design. “Laborelec reverse-engineered the entire in-stallation internally. It was about 25 meters long, nine meters high

and six meters wide. Given the pioneering nature of the task, we had to allow for modifi cations. We selected EPLAN Electric P8 in combination with EPLAN PPE partly because of the ease and speed with which they could ac-commodate changing require-ments.”

Getting up to speed with EPLANVan den Broek had used EPLAN 5 previously and was aware of its strengths. Its even more ad-vanced successor, EPLAN Elec-

tric P8, appeared to be ideal, except Van den Broek wasn’t fa-miliar with it. Almost immediately, EPLAN made an employee avail-able on a weekend for full immer-sion in EPLAN Electric P8. “Then I received another three days of intensive training, after which we set up our project standardiza-tion criteria in EPLAN. That ac-celerated the production of no

fewer than 1,100 electrical dia-grams as well as modifi cations. I don’t think this would have been possible without EPLAN,” reports Van den Broek.

Platform delivers real benefi tsUsing EPLAN PPE, Pro-Engineer-ing Design specifi ed the P&IDs, and then developed the sche-matics in EPLAN Electric P8.

Since both programs share the same database, data can be transferred effortlessly between them, avoiding duplications and errors, and thereby resulting in huge time savings. EPLAN also set up master data to further au-tomate design such as symbols, macros, other recurrent content, and a parts database EPLAN de-veloped with Schneider Electric. “EPLAN and Schneider Electric pulled out all the stops so we could meet our very tight dead-lines,” says Van den Broek.”

Documention at the highest levelBut would it work at the South Pole? EPLAN incorporated a high level of support documenta-tion in the diagrams. Clicking on a hyperlink opens up technical microfi che and full component documentation, which is why commissioning went very smooth-ly. “I am very pleased about that, because sending an EPLAN employee to Antarctica to pro-vide onsite application support was out of the question. They are extremely isolated down there,” says Van den Broek.

“EPLAN and Schneider Electric pulled out all the stops so we could meet

our very tight deadlines.”

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Vincent Van den Broek, Pro-Engineering Design

Date Exhibition Name Location Country

2010.01.12-16 SWISSBAU in Basel Basel Switzerland2010.01.20-24 Elecrama 2010 Mumbai India2010.01.21-26 IMTEX Forming Bangalore India2010.01.27-29 IFAM Dnevi Avtomatike in Mechatronike Celje Slovenia2010.02.04-11 EMC Gombloux - laakdal Belgium2010.02.08-10 Automotive Engg Expo Pune India2010.02.09-11 Middle East Electricity Dubai United Arab Emirates2010.02.25-23 INDUSTRY EXPO 2010 Bratislava Slovakia2010.03.02-04 Expomanufactura 2010 Monterrey, N.L. México2010.03.03-06 AIMEX COEX, Seoul Korea2010.03.08-11 SIAF Guangzhou China2010.03.09-11 Wetex Dubai United Arab Emirates2010.03.16-18 Aqua H2O Gorinchem Netherlands2010.03.19-22 SYSKEVASIA 2010 ATHINA GREECE2010.03.22-26 INDUSTRIE PARIS 2010 Paris-Nord Villepinte France2010.03.23-26 AUTOMATICON 2010 Warszawa Poland2010.03.23-26 Intertraffic RAI Amsterdam Netherlands2010.03.23-26 MagyarRegula Budapest Hungary2010.03.24-26 Australasian Oil & Gas 2010 Perth Australia2010.03.31 - 04.02 SMT/PCB and Packaging Korea 2010 COEX, Seoul Korea2010.04.01-03 Shenyang Instrument & Automation Shenyang China2010.04.13-16 FEAAI - Electro-Electronic & Ind. Automation Joinville - SC Brazil2010.04.13-16 AMPER 2010 Praha Czech2010.04.13-16 Bulkontrola Sofia Bulgaria2010.04.15-17 Chengdu Instrument & Automation Chengdu China2010.04.18-20 El & Teknik Messe Odense Congress Center, Odense Denmark2010.04.19-21 Oil & gas West Asia Muscat Oman2010.04.19-23 Hannover Messe Hannover Germany2010.04.21-23 Power Gen 2010 Delhi India2010.06.10-11 ISA Expocontrol México D.F. México2010.05.02-05 EDZ conference Šibenik Croatia2010.05.4-7. ElectroSalon Budapest Hungary2010.05.04-07 BIAS Biennale Internazionale dell‘Automazione Strumentazione Microelettronica Milan Italia2010.05.14-17 Automotive Engg Expo Chennai India2010.05.18-20 Global electric power tech COEX, Seoul Korea2010.05.18-20 Elmia Motek Jönköping Sweden2010.05.18-20 ABB Automation and Power World 2010 Houston, Texas USA2010.05.31-06.03 Eliaden Oslo Norway2010.06.02-05 Manufacturing Surabaya 2010 Surabaya Indonesia2010.06.06-08 WEPower 2010 Dammam Saudi Arabia2010.06.08-10 Power-Gen RAI Amsterdam Netherlands2010.06.15-18 TENAGA Expo & Forum 2010 Kuala Lumpur Malaysia2010.06.22-23 Fertigung & Instandhaltung Wels Austria2010.05.27-30 AMBINERGIA Porto Portugal2010.05.31-06.03 Eliaden Oslo Norway2010.09 PEMEX Veracruz México2010.09.27-10.02 International Technical Fair Plovdiv Bulgaria2010.09.07-09 Automatik Brøndby hallen, Copenhagen Denmark2010.09.13-17 Westwick Farrow Regional Roadshow North Queensland Australia2010.09.13-17 MSV 2010 Brno Czech2010.09.14-16 ENERGETAB 2010 Bielsko - Biała Poland2010.09.15 IEAS Bucharest Romania2010.09.15-17 Elenex Vietnam 2010 Ho Chi Minh Vietnam2010.09.21-24 Automation 2010 Pune India2010.09.22-24 Factory & process automation Brussels Belgium2010.10.03 - 04.02. Motion Control Show COEX, Seoul Korea2010.10.04-08 Electra Mining Exhibition Johannesburg South Africa2010.10.05-07 Tekniikka Jyväskylä Finland2010.10.05-08 Industry & Automation Jaarbeurs, Utrecht Netherlands2010.10.05-08 ELO-SYS 2010 Trenčín Slovakia2010.10.11-13 DAMEX EXCO, Daegoo Korea2010.10.12-16 Viennatec Wien Austria2010.10-26-28 Scanautomatic / Process Göteborg Sweden2010.11.01-03 PowerGen Doha Qatar2010.11.01-04 ADIPEC Abu Dhabi United Arab Emirates2010.11.02-04 Power Gen Asia 2010 Marina Sands Bay Singapore2010.11.03-04 Automation Fair 2010 Orlando, Florida USA2010.11.09-11 Brazil Automation ISA 2010 São Paulo - SP Brazil2010.11.09-13 FAA Factory Automation Shanghai China2010.11.10-13 EMAF Porto Portugal2010.12 Elektro Vakbeurs Hardenberg Hardenberg Netherlands2010.12.15-18 Industrial Automation Mumbai India

12

ImprintPublisher:EPLAN Software & ServiceGmbH & Co. KGAn der alten Ziegelei 2D-40789 Monheim am RheinTelefon: +49 (0) 21 73/39 64 - 0Telefax: +49 (0) 21 73/39 64 - 25www.eplan.deinfo@eplan.de

Layout:MEDIABRIDGES® GmbHAgency for Corporate CommunicationPictures: MEDIABRIDGES®, photocase, fotolia a. o.

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mEPLAN TrAdE FAirs iN 2010