BOMAG GmbH and WAGO Shake Things Up
The Dirt on BOMAG
BOMAG GmbH knows hard work. The compaction technology leader makes the world move, it’s products compact lime on cliffs, move sand in the Sahara and crush trash in suburbia. BOMAG built its rock-solid reputation on dependability and flexibility, and has chosen the WAGO X-COM-SYSTEM of terminal blocks and connectors to get it done.
Drumming up Good Vibrations
BOMAG’s top-tier steamrollers are 14-ton, diesel-powered workhorses that can be outfitted with one or two massive steel drums for compacting the hardest surfaces. In fact, BOMAG steamrollers can produce 20G of vibration for specialized construction.
“We develop the level of vibrations that are normally avoided by other commercial vehicle producers,” boasted Robert Laux, BOMAG’s head of Electronic Development.
Extraordinary vibration is not the only challenge BOMAG’s electronics must withstand; the products are subjected to steamy tropical jungles, sub-arctic windblasts and oppressive UV rays while minerals, such as lime, seep into every nook and cranny. BOMAG’s switching boxes must have sufficient ventilation while proving tough enough for extreme compaction.
However, those aren’t BOMAG’s only obstacles.
Some Like it Hot
Whether in Dubai or Siberia, comfort and safety matter, and have driven BOMAG to equip steamrollers with luxuries such as electronic stability control and air-conditioned cabins. Despite this, BOMAG has remained true to its technical motto of “simple, but robust” as it sought to prevent contact problems from halting 14-ton compactors and creating costly on-site troubleshooting.
With all of BOMAG’s requirements, a completely new electronic solution to an age-old problem was needed.
WAGO: The Switch Masters
The first step that the BOMAG engineers were already looking into was the "switch box" that contained its central electronic distribution. The existing wiring system took up too much space and was not flexible. The solution was in the switch box: rail mounted terminal blocks with CAGE-CLAMP®-conneciton, that offer more distribution options:
The terminal blocks are vibration safe. The required fatigue resistance of up to 5 g at 30 Hz, is easily met.
The terminal blocks are flexible. Any accessories can be easily added in the field at any time -- a little room on the rail is all that is needed. Even in compact machinery with limited area, the overview remains.
The terminal blocks are compact and save time on wiring. They are already compact because of their design. Using multiple conductor terminal blocks and jumpers allows more potential to be distributed. Some terminal blocks accept car fuses which saves a seperate fuse box and wiring. Furthermore, the fuses placed in a locked distribution unit are tamper resistant.
WAGO’s Earth-Shattering Solutions
BOMAG still needed stout connectors — try producing a 14-ton steamroller with out them! The versatility of WAGO’s X-COM-SYSTEM saved the day: WAGO created custom connectors tough enough to withstand compaction, yet are just 59mm high. With the X-COM-SYSTEM, WAGO created receptacles that function similarly to rail-mounted blocks and designed the receptacles to connect with modular female connectors. WAGO also engineered an angled version, which can be combined with a double-deck receptacle. The newly designed components were met with such interest that they have since become a WAGO catalog staple.
“WAGO’s largest advantages are mechanical and electrical load capacities,” said Martin Werner, BOMAG’s electronic technology development specialist. “We primarily use a 12 V nominal voltage in our machines. This results in currents that other systems cannot withstand.”
By implementing WAGO’s complete solutions, BOMAG benefited by:
- flexible development, which allows for multiple system re-configurations.
- availability of complete, system-compatible cable trees.
- no need for specialty tools. CAGE-CLAMP® connections can be handled by a screwdriver.
The WAGO-X-COM-SYSTEM has enabled BOMAG to enjoy:
- shorter assembly line run times, as no electronic installations are necessary.
- minimal service without specialty tools.
- easy testing — the system may be plugged in or one conduct or can be removed, redirected and exchanged.
- field convenience. External service personnel often perform service in harsh conditions.
This last point is particularly appealing to Laux. Yet that is not the only driver of his satisfaction with WAGO.
“We cannot expect the same conditions in the jungles of South America as we can Europe; yet, we need to solve all arising problems,” Laux said. “For this reason, we pay close attention to good product service, and we are very satisfied with WAGO. With an excellent sales force, both prototypes and samples receive the same level of support as products do after the initial sale. If a problem does occur, WAGO quickly manages it.”
BOMAG has since integrated WAGO solutions into additional business units. For example, BOMAG’s Head Maintenance Electrician, Robert Schmitz, uses WAGO terminal blocks for 2, 5 mm² to 95 mm² conductors. After comparing WAGO’s POWER CLAMP to screw-style terminal blocks, BOMAG determined the POWER CLAMPS’ more narrow width and overall price/benefit edge were superior to the competition.
BOMAG’s success with WAGO components proves that sometimes the smallest bits can make the biggest impacts.
