Applications

Connecting technology in mechanical engineering

Even when buzz words such as "embedded systems" or "IPC" dominate forums for switching station design and construction, electrical connection technology still continues to form the basis for reliable control systems. And there are always new innovations in this sector, too, such as spring clamp terminal blocks for conductor cross sections up to 95 mm².A closer look at the machines in the Fischer machine plant illustrates the wide spectrum of modern control cabinet design.Fischer uses WAGO rail-mounted terminal blocks and connectors in their products.

The company Karl Eugen Fischer GmbH, headquartered in the Franconian community of Burgkunstadt in Germany has achieved success in a number of niche markets. The company is, for example, the world leader in the production of cord cutting systems that are indispensable for tire production. Prefabrication of fabric and steel cord requires a great deal of expertise, as the materials that are used are extremely sensitive to tensile stress and other similar mechanical loads. It is also very sticky. Nearly every machine used in this field is a one-of-a-kind, as they must be designed and manufactured for each specific customer.

Fischer also calls the tune in their second business sector, sheet metal processing, using extremely fast and versatile stand-alone angle cutters and CNC-controlled press brakes. Unfinished panels 6.4 mm thick are run through the angle cutters at speeds up to 80 m/min and positioned accurately to the nearest 0.05 mm, where they are cut in less than one second into stamp-size pieces measuring 1.5 m². The CNC-controller press brakes generate pressing forces of up to 2000 kN. One can easily image the vibrations that are created when these machines are in operation. That is why Fischer uses top-class connecting technology in their products, because with customer throughout the world service assignments and travel can be rather expensive.

Master electrician Uwe Thurn, head of electrical installations at Fischer recalls: "We even had to fly to Asia for servicing because of loose connectors. We switched to using WAGO connector modules toward the end of the 90s and after that problems like that one seem to have vanished. Although some customers were somewhat skeptical about spring clamp terminal blocks they soon changed their minds. WAGO is practically our standard technology now." Uwe Thurn knows this field, because a large portion of the control systems used are produced directly at Fischer. Outside companies are only contracted for control cabinet construction when bottlenecks occur. The entire spectrum of the WAGO rail-mounted terminal block program is employed, starting from the small 33.5 mmlong, 2-wire block of Series 870, up to the "95er" of the sole spring-clamp terminal block currently offered for cross sections up to 95 mm². Even more space-saving triple-deck terminal blocks of the 870 Series are also used. Thomas Gross, second in command of electrical installations explains: "The triple-deck terminal block requires less space while at the same time providing a plain and clearaly laid-out structure thanks to the number of marking options available.“

Besides compact designs, Fischer also utilizes other possibilities for saving space with connecting modules. This includes connecting modules with additional functions. For example, signal splitting required for linking to CNC control systems is implemented using modules with integrated diodes. This does away with the need for separate components and additional wiring. Uwe Thurn has this to say: "We are happy to make details known to our customers, such as the particularly reliable connecting technology that we use. This allows us to convince them of the consistently good quality of our products.“
Connectors from the WAGO program are also used. The boards in the operator panels are equipped with the MULTIPLE CONNECTOR system. Other systems that were used prior to this could not stand up to the ambient conditions that were prevalent.