Enclosure manufacturing is under enormous pressure to transform: increasing complexity, growing competitive pressure and the continuous shortage of skilled workers are intensifying the need for automated, end-to-end digital processes. There is enormous potential in the wiring process in particular: it is traditionally one of the most time-consuming and error-prone activities in enclosure production. This is precisely where modern solutions from Rittal Automation Systems (RAS) and Eplan come in - from automated wire assembly and intelligent wire logistics to fully digitally controlled production.

Automated processes as an answer to the shortage of skilled workers

In traditional switch cabinet construction, manual wiring often takes up to 50% of the total production time. It causes high personnel costs and is prone to errors. Automation offers the opportunity to sustainably reduce this key hurdle and increase production quality at the same time.

RAS and Eplan have been driving automation in control and switchgear manufacturing for years and developing solutions that are based on digital engineering data and optimize the entire process.

© Rittal

Wire terminal: ready for wiring up to 15 times faster

A central component is the automated wire assembly process. Depending on the version, up to 36 different wires can be produced automatically using modern fully automatic machines - including cutting to length, stripping, crimping, labeling and project-related picking.

The result:

• Up to 15 times faster wire assembly
• Consistently high quality, as all steps are reproducible
• rapid amortization, often from approx. 300 control cabinets per year

This creates a stable basis for automated and scalable production processes - regardless of the availability of experienced specialists.

Wire handling system: just-in-time wire logistics for maximum productivity

The greatest increase in efficiency is achieved when automated wire assembly is combined with intelligent wire logistics. This is precisely where the wire handling system from RAS comes in: it automatically transports pre-assembled wires to up to four workstations using compressed air - just-in-time, just-in-sequence and over distances of up to 80 meters.

The advantages for production managers and production planners:

• Reduced walking distances and intralogistics costs
• fewer search and waiting times
• More order and structure in the workplace
• high process reliability thanks to sequentially planned wire provision

Even less experienced employees can wire efficiently and with minimal errors - a decisive advantage in times of a shortage of skilled workers.

Eplan Smart Production: Digital production for enclosure construction

© Eplan

With Eplan Smart Production, enclosure construction becomes an end-to-end digital process: engineering data becomes the heart of production. It flows directly into the assembly and processing machines, controls their tasks and ensures full transparency across every production step.

The digital twin from Eplan makes it possible:

• Automatic derivation of processing and wiring programs
• Seamless data consistency from engineering to production
• Optimized sequences, error prevention and reliable documentation

Eplan Smart Production thus combines the engineering and manufacturing worlds into a holistic system - a key component for maximum efficiency in modern control and switchgear manufacturing.

Eplan Smart Wiring: Assistance for employees - regardless of their level of experience

Eplan Smart Wiring uses the same engineering data and guides employees step by step through the wiring process - including 3D visualization, cable lengths, target points and automated plausibility checks.

This makes wiring:

• simpler because it is visually guided
• safer, because errors are detected early
• faster because all information is available digitally
• less dependent on empirical knowledge, which increases flexibility

Especially in combination with the wire handling system, well-rehearsed processes are created that are productive and quality-assured.

Consistency is key: from engineering to production

Together, Rittal Automation Systems and Eplan offer an integrated ecosystem that goes far beyond individual automation islands.

From the digital twin to automated production and physical assembly, an end-to-end process is created that optimally positions companies for the future:

• growing production volumes
• increasing demands on documentation
• time-critical projects
• bottlenecks in skilled labor
• ambitious growth targets

Conclusion: Automation with Rittal Automation Systems and Eplan creates future security

The combination of Wire Terminal, Wire Handling System and Eplan Smart Production sets new standards in enclosure construction. Companies benefit from:

• massive time and cost savings
• end-to-end digitalized processes
• reduced workload for skilled workers and greater flexibility
• standardized quality and reproducible results

Those who rely on integrated solutions today secure clear competitive advantages - and make their own production fit for the challenges of the future.

Visit Rittal and Eplan during the Hannover Messe, Hall 27 Stand D50