Project Overview: Industrial Automation Upgrade
In early 2023, a leading automotive manufacturing plant in Germany embarked on a comprehensive automation upgrade to increase production efficiency and reduce downtime. The project involved installing over 200 new sensors, actuators, and control devices across three production lines.
The existing electrical distribution system was outdated and couldn't accommodate the new smart devices. Engineers needed a robust, flexible solution that could handle increased connectivity requirements while withstanding the harsh industrial environment.
Technical Challenges
The engineering team faced several significant challenges in implementing the new automation system:
- Space constraints: Limited panel space required compact yet high-capacity distribution solutions
- Environmental factors: Dust, moisture, and temperature fluctuations demanded IP67-rated enclosures
- Signal integrity: Sensitive sensor signals needed protection from electromagnetic interference
- Maintenance requirements: Quick access for troubleshooting without disrupting production
- Future expansion: The system needed to accommodate potential future upgrades
TSM Distribution Box Solution
After evaluating multiple options, the engineering team selected the TSM-Series Distribution Box for its superior features and flexibility. Specifically, they deployed 18 TSM-18 units throughout the production facility.
The TSM Distribution Boxes provided:
- IP67 protection against dust and moisture
- High-density terminal arrangement saving 40% space compared to alternatives
- EMI shielding for sensitive sensor signals
- Clear marking and identification systems
- Tool-less access for maintenance and modifications
Key Benefits Realized
- Reduced installation time by 35% compared to traditional methods
- Eliminated signal interference issues that plagued previous systems
- Provided flexibility for last-minute design changes without rewiring
- Enabled future expansion with 30% spare capacity
Installation Process
The installation team followed a systematic approach to implement the TSM Distribution Boxes:
- Planning: Detailed mapping of all connection points and signal types
- Mounting: Secure installation of distribution boxes at strategic locations
- Wiring: Organized cable routing with proper strain relief
- Termination: Precision connection of all field devices
- Testing: Comprehensive verification of all signals and connections
- Documentation: Complete labeling and system documentation
The modular design of the TSM boxes allowed the installation to proceed in phases, minimizing disruption to ongoing production operations.
Results & Benefits
The implementation of TSM Distribution Boxes delivered significant measurable benefits:
- 30% reduction in installation time compared to previous methods
- Zero signal integrity issues reported since implementation
- 40% less space required for electrical distribution
- 67% faster troubleshooting and maintenance access
- 100% uptime during the transition period
"The TSM Distribution Boxes were instrumental in the success of our automation upgrade," said Karl Schmidt, Lead Project Engineer. "Their compact design, reliability, and ease of installation helped us complete the project ahead of schedule while exceeding performance expectations."
The manufacturing plant has since standardized on TSM Distribution Boxes for all future expansion projects and has recommended them to other facilities in their global network.