Complete system solutions from a single source
Complete system solutions from a single source
Complete system solutions from a single source
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Rittal – The System.<br />
Faster – better – worldwide.<br />
<strong>Complete</strong> <strong>system</strong> <strong>solutions</strong> <strong>from</strong> a <strong>single</strong> <strong>source</strong><br />
REFERENCE BROCHURE Industry
The perfect customer solution<br />
with “Rittal – The System”<br />
When it comes to achieving comprehensive protection of electronics<br />
and electrical engineering, the requirements can vary considerably.<br />
For mechanical engineers, the energy effi ciency of the <strong>system</strong> is an<br />
increasingly important consideration, alongside reliability. They will tend<br />
to focus on economical cooling units. The same applies to the auto<br />
industry, which also uses enclosures in a wide range of sizes: <strong>from</strong><br />
the TS 8 large enclosure through to small, compact and operating<br />
enclosures. Meanwhile, other customers attach particular importance<br />
to data consistency and use Rittal <strong>solutions</strong> at the engineering stage.<br />
Finally, an airport like Berlin Schönefeld is particularly appreciative of the<br />
safety standards of Ri4Power low-voltage switchgear. All these requirements<br />
are met by the “Rittal – The System” modular range, with carefully<br />
coordinated components and software tools. This is complemented by<br />
individual <strong>system</strong> advice, an extensive range of accessories, and global<br />
customer service.<br />
Over the next few pages, read how companies <strong>from</strong> a wide range of<br />
industries use “Rittal – The System” and have discovered their own<br />
perfect solution. Allow yourself to be inspired. I am confi dent that “Rittal<br />
– The System” will accommodate your requirements too.<br />
Bernd Eckel<br />
President Sales
Rittal – The System.<br />
Solutions <strong>from</strong> industry,<br />
for industry<br />
Rittal operates a professional sector management <strong>system</strong>. The Herbornbased<br />
technology fi rm concentrates on established markets such as<br />
mechanical engineering, information technology and transport technology.<br />
Rittal also selectively targets future sectors such as renewable<br />
energies and electromobility. Through our close, face-to-face contact<br />
with customers, we devise creative <strong>solutions</strong> based on the modular<br />
<strong>system</strong> platform “Rittal – The System” in order to boost energy effi ciency,<br />
for example. Our regular exchanges with leading industry representatives<br />
enable Rittal to identify future trends early on. Our product development<br />
teams pick up on these trends and develop innovations in<br />
collaboration with customers, before positioning them on the market.
Rittal on the Weisser greenplus project<br />
Trimming the electricity consumption<br />
of lathes<br />
With the pioneering project greenplus, Thorsten Rettich, Head of Design at J. G. Weisser Söhne, demonstrates that even<br />
the optimised production <strong>system</strong> Univertor AC is still capable of achieving savings of up to 48%.<br />
The energy-saving potential of machine tools is still<br />
far <strong>from</strong> exhausted: With their greenplus project, manufacturers<br />
J. G. Weisser Söhne based in St. Georgen<br />
in the Black Forest demonstrate that it is still possible<br />
to double energy effi ciency, even in high-tech plants.<br />
This is made possible by a combination of different<br />
optimisation <strong>solutions</strong>, including Cool Effi ciency<br />
cooling units <strong>from</strong> Rittal.<br />
As a rule of thumb, acquisition costs only account for<br />
one-third of the overall costs of machine tools. In order<br />
to minimise unit costs in the production chain, you also<br />
need to address the downstream costs.<br />
According to the Fraunhofer Institute for Production<br />
Technology and Automation, around 20% of the total<br />
costs over a machine tool’s service life are attributable to<br />
energy consumption. This prompted Weisser to develop<br />
an energy effi ciency programme for the internationally
popular machine tool series Univertor and Vertor.<br />
“Low unit costs are the key competitive factor for our<br />
customers. We must therefore pull out all the stops to<br />
achieve this goal”, comments Thorsten Rettich, Head<br />
of Design at Weisser. When it comes to energy-effi cient<br />
production, the company far exceeds the usual standards,<br />
as illustrated by the ambitious project greenplus<br />
for Univertor AC. greenplus has been proven to cut the<br />
primary energy consumption of this hard turning lathe<br />
by 48%. The project is part of Weisser’s comprehensive<br />
strategy to minimise unit costs. For transparency reasons,<br />
the greenplus project has been sub-divided into<br />
various function groups: the rotary lathe, Hydro & Air and<br />
Cooling technology processes developed and patented<br />
by Weisser.<br />
Effi cient through and through<br />
The rotary lathe <strong>system</strong> achieves savings of up to 77%<br />
compared with other hard turning and grinding techniques.<br />
Firstly, sealing surfaces e.g. for gear shafts<br />
can be produced in a much shorter time. Secondly,<br />
this technique replaces grinding and superfi nishing<br />
processes by producing twist-free surface fi nishes.<br />
There is plenty of energy-saving potential with rotary<br />
lathes.<br />
Hydro & Air uses innovative compact hydraulics combined<br />
with effi cient pneumatics. This avoids heat loss<br />
and leakage, and improves running and switching behaviour,<br />
which in turn increases effi ciency and signifi cantly<br />
reduces power consumption.<br />
For cooling, Weisser uses Cool Effi ciency cooling units<br />
<strong>from</strong> Rittal. They cool the controller in machine-integrated<br />
enclosures. Recoolers are also used for process cooling.<br />
Measurements in automobile factories have shown<br />
that <strong>solutions</strong> <strong>from</strong> Rittal cut energy consumption by<br />
45% compared with conventional cooling units. This is<br />
achieved by the optimum interplay between innovative<br />
fans and refrigerating compressors plus perfectly positioned<br />
heat exchangers and electronic fi ll level control<br />
for coolants.<br />
Intelligent cooling alone achieves savings of around<br />
465 kilowatt hours per annum with a <strong>single</strong> Univertor<br />
machine. Since most of Weisser’s customers use 200<br />
or more machines, with greenplus, this translates into<br />
energy cost savings of more than 86,000 Euros per<br />
annum, of which the Rittal <strong>system</strong>s account for around<br />
10,000 Euros.<br />
For process cooling, a recooler <strong>from</strong> Rittal is used in<br />
addition to Cool Effi ciency cooling units.
Integrated <strong>system</strong> solution <strong>from</strong> Rittal<br />
A stable energy supply<br />
for new Berlin airport<br />
Construction work at the BBI site, which covers the equivalent of 2,000 football pitches, has been underway since<br />
September 2006. The new airport in the German capital Berlin is scheduled to open its doors in 2011.<br />
Since September 2006, work has been underway to<br />
expand Schönefeld as Germany’s new capital city<br />
airport. An initial capacity of up to 27 million passengers<br />
has been planned for 2011, with the option of<br />
expanding this fi gure to 45 million per annum as and<br />
when required. At this point, the airport will be consuming<br />
roughly the same amount of electricity as a<br />
city of 70,000 households. Transformer and distributor<br />
stations, some of which are equipped with Ri4Power<br />
power distribution <strong>system</strong>s <strong>from</strong> Rittal, will ensure a<br />
stable energy supply.<br />
Flughafen Berlin-Schönefeld GmbH bundled the contracts<br />
for construction and planning services at the<br />
airport into several large tenders. One of these, tender<br />
GU XII, comprised all the wiring for the site, including<br />
the construction of a total of 22 transformer stations<br />
to supply all elementary equipment such as the control<br />
tower, fi re brigade and data centre. The contract for<br />
GU XII was awarded to a consortium, including Areva<br />
and Westmontage as well as Berlin-based Elpro GmbH.<br />
The owner-managed company Elpro is responsible for<br />
the low-voltage switchgear in eight of the 22 power stations.<br />
Its duties will include all the work stages for some
41 circuit-breaker sections and 40 switch-disconnectorfuse<br />
sections, <strong>from</strong> engineering and production through<br />
to assembly, commissioning and servicing. The airport’s<br />
requirements are very exacting. For example, the invitation<br />
to tender specifi es the form of separations for<br />
switchgear and short-circuit resistance of up to 100 kW<br />
throughout, right down to the distribution busbar.<br />
Meticulously planned power distribution<br />
Form-separated switchgear affords a high level of safety,<br />
because the risk of contact with live parts is virtually<br />
excluded, both during installation and commissioning,<br />
as well as during subsequent maintenance work. Elpro<br />
achieved the form separation of the switchgear using<br />
Ri4 Power low-voltage switchgear <strong>from</strong> Rittal, using as<br />
its basis the TS 8 Top enclosure <strong>system</strong> with modular<br />
separation for Forms 2 to 4. The reliability and safety<br />
of the Ri4Power <strong>system</strong> has been verifi ed by external<br />
laboratory testing with switchgear <strong>from</strong> numerous reputable<br />
manufacturers. Unlike its competitors, Rittal does<br />
not charge any licence fees for the use of Ri4Power.<br />
One major benefi t is the broad range of accessories<br />
available for the modular TS 8, ranging <strong>from</strong> enclosure<br />
lighting to climate control. When it comes to busbars,<br />
clients can choose between Maxi-PLS and Flat-PLS.<br />
Elpro opted for Maxi-PLS for the airport project, because<br />
this variant is particularly well-suited to switchgear in<br />
the heavy-current range. Maxi-PLS bars have a square<br />
cross-section with T grooves on all four sides. As a<br />
result, the connection <strong>system</strong> obviates the need for<br />
time-consuming machining. Due to the sheer scale of<br />
the airport site, large numbers of parallel cables needed<br />
to be connected to the switchgear. With the Maxi-PLS<br />
bars, this task was achieved in a compact, manageable<br />
and time-effi cient manner.<br />
Computer-assisted project planning using the Power<br />
Engineering planning tool <strong>from</strong> Rittal likewise helped<br />
Elpro to achieve high levels of effi ciency. The software<br />
operates seamlessly with the CAE <strong>system</strong> <strong>from</strong> Elpro,<br />
so that the enclosures could be confi gured on the PC<br />
in a user-friendly manner. The related parts lists were<br />
generated automatically. The switchgear is scheduled<br />
to commence operation in spring 2010. The project ran<br />
very smoothly, thanks to close collaboration within the<br />
GU XII consortium. “The meticulously planned technology<br />
behind the Ri4Power <strong>system</strong> was a signifi cant factor<br />
here”, summarises Elpro project manager Martin Kopf.<br />
Martin Kopf at Elpro is responsible for the planning<br />
and production of low-voltage switchgear in the GU XII<br />
sub-project at Berlin Brandenburg International Airport.<br />
The Elpro <strong>system</strong> in the airport control tower, created<br />
using Ri4Power.<br />
Staff at Elpro GmbH produce switchgear at their<br />
4,000 square metre plant.
Rittal at Frankfurt Rhine-Main Airport<br />
Outstanding versatility<br />
Hubert Grünewald, Head of Operations and Baggage Systems at Fraport, is a fi rm believer in the reliability of<br />
Rittal <strong>solutions</strong>.<br />
With more than 50 million passengers, Frankfurt<br />
Airport is a global hub for international air traffi c. For<br />
many years, its operator company Fraport has used<br />
integrated <strong>system</strong> <strong>solutions</strong> <strong>from</strong> Rittal to ensure<br />
the reliable functioning of various applications and<br />
<strong>system</strong>s. A glimpse behind the scenes demonstrates<br />
the diverse ways in which “Rittal – The System”<br />
ensures uninterrupted operation at the airport,<br />
both in baggage handling and in the data centre.<br />
Right: Germany’s largest airport makes extensive use of Rittal <strong>system</strong> technology.<br />
The baggage handling <strong>system</strong> at Frankfurt Airport<br />
measures 73 kilometres. On peak days, it transports<br />
up to 120,000 cases and bags. Technical malfunctions<br />
must be avoided at all costs; and for this reason, Fraport<br />
will only consider technology that guarantees maximum<br />
availability. For example, Terminals 1 and 2 contain hundreds<br />
of TS 8 enclosure <strong>system</strong>s and more than 300 CM<br />
compact enclosures <strong>from</strong> Rittal. The modular <strong>system</strong>s<br />
protect the control technology for the vast baggage<br />
handling <strong>system</strong>.
In this way, Fraport achieves 99.65% availability. “This<br />
high level of reliability is a major competitive advantage<br />
for Frankfurt Airport”, comments Herbert Grünwald,<br />
Head of Operations for Frankfurt baggage handling<br />
<strong>system</strong>s.<br />
The rollercoaster-like <strong>system</strong> connects Terminals 1 and<br />
2 via a <strong>system</strong> of tunnels spanning several kilometres.<br />
Baggage is transported in standardised containers.<br />
A high-tech precision <strong>system</strong> with readers and scanners<br />
transports containers quickly and reliably to their destination<br />
via countless track switches. En route, they pass<br />
through multi-level control <strong>system</strong>s, whereby every<br />
container is automatically scanned by an X-ray unit.<br />
The highly sensitive control electronics are housed in<br />
TS 8 enclosures, as is the power distribution. Because<br />
many of these components produce considerable<br />
amounts of waste heat, the enclosures are equipped<br />
with TopTherm cooling units <strong>from</strong> Rittal.<br />
Rittal TS 8 enclosures and TopTherm cooling units in the<br />
baggage handling <strong>system</strong> at Frankfurt Airport.<br />
Unlike their “big brother” TS 8, the smaller CM compact<br />
enclosures are used in a front line position, directly<br />
adjacent to the conveyor belts. PLC outputs for sensors<br />
and actuators are securely housed in these CM<br />
enclosures. CM and TS 8 illustrate the comprehensive<br />
<strong>system</strong> concept behind Rittal’s platform: The extensive<br />
TS 8 assembly and accessory range may also be used<br />
without restriction for CM.<br />
Effective cooling<br />
Rittal’s <strong>system</strong> concept is also highly effective when it<br />
comes to upgrading existing enclosure <strong>system</strong>s, as<br />
illustrated by the network station for Terminal 2 at<br />
Frankfurt Airport, where all data, voice and video communication<br />
converges: Over the years, more than<br />
50 TS 8 racks had become ever more densely packed<br />
with switches and network technology. Waste heat<br />
levels increased rapidly; the thermometer in the network<br />
room climbed to 40 degrees. Fraport came up with a<br />
The CM compact enclosures are used in a front line<br />
position, directly adjacent to the conveyor belts.
surprisingly simple solution which entailed retrofi tting an<br />
LCP Extend climate control <strong>system</strong> <strong>from</strong> Rittal while the<br />
<strong>system</strong> was operational. It consists of preassembled<br />
climate control doors that are fi tted to the rear of the<br />
rack in just a few actions. Its air/water heat exchanger<br />
achieves a throughput of 3,000 cubic metres per hour,<br />
and can withstand a total heat loss of up to 12 kW per<br />
enclosure. A total of 16 TS 8 racks were upgraded using<br />
LCP Extend. Since then, the room temperature has<br />
remained constant at between 20 and 22 degrees.<br />
Once again, Rittal has demonstrated how its integrated<br />
<strong>system</strong> concept produces fast, pragmatic <strong>solutions</strong>, and<br />
affords reliable protection for previous investments.<br />
The entire communications technology for Terminal 2 is<br />
housed in TS 8 racks. The excellent climate control is<br />
achieved by numerous LCP Extend units in the form of<br />
air/water heat exchangers.<br />
The aircraft on the apron need a reliable power supply, ideally protected by enclosures <strong>from</strong> Rittal.
Rittal in the automobile industry<br />
Prescribed as standard<br />
The automobile industry is a key sector of the<br />
German economy. German cars owe their market<br />
success to the unremitting innovative strength of<br />
Germany’s manufacturers and suppliers.<br />
“Rittal – The System” has proven highly successful<br />
throughout many sectors: <strong>from</strong> production control<br />
and low-voltage power distribution, through to IT<br />
networking.<br />
Be it Volkswagen, Audi, Daimler, Opel, Ford, Porsche or<br />
BMW – for years, Rittal has been a <strong>system</strong> supplier to<br />
the German automobile industry. Enclosures, housings<br />
and climate control <strong>solutions</strong> <strong>from</strong> Rittal have become<br />
established as the standard throughout many areas of<br />
the German auto sector. At international level, too, the<br />
high-tech company <strong>from</strong> Herborn has secured its place<br />
as the preferred supplier to many well-known brands,<br />
When it comes to <strong>system</strong> <strong>solutions</strong> for enclosure and case technology, for many years, Rittal has been established as<br />
the <strong>system</strong> supplier for all German car manufacturers – Volkswagen, Audi, Daimler, Opel, Ford, Porsche and BMW.
thanks primarily to the comprehensive and holistic<br />
product portfolio <strong>from</strong> Rittal: <strong>from</strong> the TS 8 enclosure<br />
<strong>system</strong>, to small and compact enclosures and operating<br />
panels, through to power distribution and <strong>system</strong> climate<br />
control. This is complemented by complete <strong>solutions</strong> for<br />
energy-effi cient data centres. For example, Volkswagen<br />
uses Rittal RimatriX5 for its IT <strong>system</strong>s in Russia, India,<br />
Brazil and the USA.<br />
Intelligent energy saving<br />
Saving energy is the top priority for car manufacturers<br />
worldwide. Concepts for reducing consumption and<br />
emissions are aimed primarily at the infrastructures of<br />
buildings, optimised production <strong>system</strong>s, and power<br />
distribution. Intelligent <strong>system</strong> climate control is an<br />
essential part of this. Rittal has undertaken long-term<br />
testing of its TopTherm cooling technology on behalf<br />
of various manufacturers, in order to verify the exceptionally<br />
low consumption of its nano-coated (RiNano)<br />
products, even in tough industrial environments. At one<br />
German manufacturer’s dusty, oily brake pad production<br />
plant, for example, cooling units <strong>from</strong> Rittal received<br />
no servicing at all for a period of 14 months. During this<br />
entire period, no dirt accumulated on the RiNano-coated<br />
condensers. Cooling performance was not impaired,<br />
and power consumption remained constant. However,<br />
proven energy effi ciency is just one of the reasons why<br />
countless production managers today prescribe nano-<br />
Rittal technology – <strong>from</strong> enclosure to climate control<br />
technology – is prescribed as standard throughout<br />
virtually all applications of the German automotive<br />
industry.<br />
coating as a binding requirement for cooling units. Other<br />
factors include savings in terms of maintenance and<br />
material consumption, together with superior reliability<br />
of controllers, thanks to stable enclosure temperatures.<br />
From January to November 2009, the new energy-saving<br />
cooling units Rittal Cool Effi ciency were tested by one of<br />
these manufacturers under the extreme ambient conditions<br />
of a pressing plant for a total of 45 weeks.<br />
The result: With Cool Effi ciency, primary energy consumption<br />
was cut by 70% compared with conventional<br />
TopTherm cooling units, saving car manufacturers<br />
almost 110 Euros per enclosure, per year. As there are<br />
typically several hundred enclosures in use, this fi gure is<br />
multiplied to a substantial fi ve-fi gure saving.<br />
It is not just reduced petrol consumption that improves<br />
a car’s eco-balance sheet, but also energy-effi cient,<br />
re<strong>source</strong>-conserving production processes. With this<br />
in mind, around 60 leading German manufacturers and<br />
suppliers joined forces to create the “Green Carbody<br />
Technologies” alliance. The initiative, which is supported<br />
by the German Ministry for Education and Research,<br />
focuses on innovative technologies and techniques for<br />
bodywork manufacturing. Rittal’s expertise in the fi eld of<br />
intelligent <strong>system</strong> climate control is one element of this.<br />
The members of the alliance are aiming to double the<br />
energy effi ciency of car production.<br />
Solutions <strong>from</strong> Rittal range <strong>from</strong> TS 8, small and compact<br />
enclosures and command panels, to power distribution<br />
<strong>system</strong>s, through to complex <strong>system</strong> climate control<br />
<strong>solutions</strong>.
Siemens WKC prefers “Rittal – The System”<br />
Perfect production of<br />
customised enclosures<br />
Hans-Peter Kasparick, Head of Process Engineering and Systems Engineering, and Olaf Günther, Head of System<br />
Solutions and Industrial Equipment, at Siemens WKC.<br />
The vast majority of the 15,000 enclosures that leave<br />
the Siemens plant in Chemnitz each year are manufactured<br />
in small quantities. Consequently, super-effi -<br />
cient, meticulously organised planning and production<br />
processes are more important than ever. Only in this<br />
way is it possible to guarantee delivery accuracy and<br />
a high standard of quality. Siemens has been successfully<br />
achieving this for the past 18 years with integrated<br />
<strong>system</strong> <strong>solutions</strong> <strong>from</strong> its main and preferred<br />
supplier, Rittal: beginning with the modular enclosure<br />
<strong>system</strong> TS 8, via cooling and power distribution components,<br />
through to innovative 3D development tools<br />
<strong>from</strong> the Hessian-based high-tech company.<br />
The Siemens combination engineering plant at Chemnitz<br />
(Siemens WKC) develops and manufactures high-quality<br />
individual enclosures for some 160 customers, predominantly<br />
manufacturers of production and machine tools as<br />
well as industrial transport <strong>system</strong>s. “We see ourselves,<br />
not as enclosure manufacturers, but as engineering<br />
partners and providers of <strong>system</strong> <strong>solutions</strong>”, says Olaf<br />
Günther, Head of System Solutions and Industrial Equipment<br />
at Siemens WKC. As such, the Chemnitz factory is<br />
not a mass production plant, but a supplier of customised<br />
<strong>solutions</strong>. Despite manufacturing to order, Siemens<br />
WKC’s short delivery times and uncompromising quality<br />
standards sets it apart <strong>from</strong> its competitors. To this end,
For switchgear engineering, 3D data <strong>from</strong> the Rittal<br />
RiCAD-3D components library and EPLAN Cabinet is<br />
used to plan the circuitry.<br />
however, throughput times must be minimised and all<br />
operations must dovetail seamlessly with one another.<br />
For this reason, Siemens WKC uses integrated <strong>system</strong><br />
<strong>solutions</strong> <strong>from</strong> Rittal throughout every phase of development<br />
and production.<br />
Engineering tools for consistency<br />
This even applies to engineering of the switchgear, which<br />
is designed using EPLAN Cabinet <strong>from</strong> the Rittal RiCAD-<br />
3D components library. Consistency throughout every<br />
development phase is guaranteed by Rittal software<br />
<strong>solutions</strong>, including their interfaces to EPLAN engineering<br />
tools. The Rittal climate calculation tool Therm is likewise<br />
integrated, enabling Siemens to perfectly dimension<br />
the cooling unit technology for the 3D enclosure at a<br />
virtual level. Computer-assisted engineering allows a<br />
wide range of parameters to be effi ciently tested in<br />
advance. All aspects requiring clarifi cation are resolved<br />
at the development phase. The entire assembly may<br />
be digitally simulated and checked for plausibility. In<br />
this way, Siemens WKC not only saves on development<br />
costs, but also shortens the process throughput time,<br />
while at the same time ensuring that all components are<br />
installed in line with the relevant standards.<br />
As soon as the virtual enclosure is complete, machining<br />
and routing follows. TS 8 enclosures <strong>from</strong> Rittal are supplied<br />
just in time by the distribution and logistics centre<br />
(VLC) in Gera, with premachining where appropriate. The<br />
NC fi les supplied by EPLAN Cabinet allow the machines<br />
at VLC to drill, punch or laser automatically at the correct<br />
positions. Hence, Rittal is more than just a supplier<br />
for Siemens WKC – it is also involved in process operations<br />
<strong>from</strong> the outset.<br />
In a subsequent stage, preassembled cable harnesses<br />
are created using the routing module <strong>from</strong> EPLAN. This<br />
means that precut and labelled cables are already<br />
available in the correct lengths at the time of assembly,<br />
leading to signifi cant production savings. Now the<br />
engineers are ready for seamless assembly of the TS 8<br />
enclosures with TopTherm cooling units.<br />
Hans-Peter Kasparick, Head of Process Engineering and<br />
Systems Engineering at Siemens WKC, explains: “One<br />
of the main reasons why we use Rittal is the availability<br />
of 3D data, the excellent links to engineering tools such<br />
as EPLAN Cabinet and P8, and the project planning<br />
support for climate control with user programs such as<br />
Therm”.<br />
Right: After assembly, the <strong>system</strong> is ready for testing. The electrical equipment is ready to “plug and play”.
Enclosures and cooling <strong>solutions</strong> in mechanical engineering<br />
“Better milling” with<br />
<strong>system</strong> <strong>solutions</strong> <strong>from</strong> Rittal<br />
“Customers have certain expectations of Hermle, and Hermle has similar expectations of its suppliers. In Rittal, we have<br />
found a technology partner on our own level”, says Manfred Schulz, Head of Procurement and Logistics at Hermle.<br />
Milling machines <strong>from</strong> Hermle AG could well be<br />
the best in the world. This precision manufacturer<br />
has already installed more than 20,000 machines.<br />
Hermle is a byword for precision, not just in Germany,<br />
but worldwide, and throughout many key<br />
industries. Its popularity is hardly surprising, since<br />
Hermle knows what customers want: Precision is<br />
paramount, followed by cost-effi ciency. Hermle<br />
believes it is equally important to drive innovation<br />
forwards, guided by the latest market trends. The<br />
best way of achieving this is with powerful partners.<br />
Consequently, Hermle has been relying on Rittal for<br />
its enclosures and <strong>system</strong> climate control since the<br />
Nineties.
TopTherm cooling units and recoolers are used for<br />
enclosure and spindle cooling.<br />
The medium-sized machinery plant Berthold Hermle<br />
AG is based in Gosheim, an area with a long tradition<br />
of precision technology and mechanical engineering.<br />
High-performance machining centres for the complete<br />
processing of a wide range of workpieces are produced<br />
here, and used by numerous key industries, <strong>from</strong> medical<br />
technology to motor sport. Quality is the <strong>single</strong> most<br />
important customer requirement. “Even in three-shift<br />
operation, our high-tech machines must still be capable<br />
of producing top-class results that last for more than<br />
ten years. That’s how long our products are generally<br />
in use”, stresses Manfred Schulz, Head of Procurement<br />
and Logistics at Hermle. Customers have certain expectations<br />
of Hermle, and Hermle has similar expectations<br />
of its suppliers. In Rittal, the company has found a technology<br />
partner on its own level. “The quality is spot-on”,<br />
says Schulz. The two medium-sized companies have<br />
a lot in common: Both have secured leading market<br />
positions through their own efforts. At both Hermle and<br />
Rittal, the customer is pivotal to everything they do. And<br />
both Hessian-based Herborn and Wuerttemberg-based<br />
Gosheim are mass producers of quality.<br />
The two companies collaborate closely, generally beginning<br />
at the product conception stage. Although Rittal<br />
supplies standard products, there are still countless<br />
details to discuss when a new machining centre is being<br />
launched on the market. Hermle has opted for the TS 8<br />
series of enclosures <strong>from</strong> Rittal. Its modular principle<br />
provides the ideal basis for individual <strong>solutions</strong>, and the<br />
The high-performance machining centres <strong>from</strong> Hermle<br />
are used for complete machining of a wide range of<br />
workpieces.<br />
standardised platform concept allows Hermle to access<br />
an extensive range of accessories. Climate control is<br />
also a pivotal consideration: TopTherm cooling units<br />
are used for enclosure and spindle cooling, as well as<br />
recoolers with a cooling output of up to 12 kW. Energy<br />
effi ciency is a major issue in this regard. “We have made<br />
it our mission to conserve re<strong>source</strong>s and offer energyeffi<br />
cient products. In recent years, this has become an<br />
important criterion. Choosing the right cooling unit is<br />
crucial”, explains Schulz. Rittal is in complete agreement,<br />
and is committed to the development of ever<br />
more economical climate control units.<br />
World-wide service<br />
When it comes to service, speed is vital. Hermle offers<br />
its customers a global service network, and draws on<br />
re<strong>source</strong>s <strong>from</strong> Rittal to achieve this. “If a malfunction<br />
occurs in Brazil, our employees will collaborate with the<br />
local Rittal service team to repair the machine as quickly<br />
as possible”, explains Schulz.<br />
Speed is also crucial for product development. In this<br />
connection, Hermle has set itself a major challenge<br />
for the future: “Our aim is to develop and market new<br />
products even faster. We want to achieve a development<br />
period of less than six months. We cannot achieve<br />
this unless our suppliers are part of the team”, stresses<br />
Schulz. Hermle and Rittal are planning to face up to this<br />
exciting challenge on the basis of a successful partnership.
Karsten Scharte, Managing Director of ISAB Klitschmar GmbH, manufactures industrial switchgear for pumping<br />
stations.<br />
Enclosure technology in the water management industry<br />
Replacing fi breglass with aluminium<br />
In many areas of the water management industry,<br />
optimum protection of the sensitive control<br />
electro nics in pumps is crucial. Be it drinking water<br />
processing, waste water treatment or groundwater<br />
level measurement, the industry demands fl exible,<br />
robust enclosure technology, particularly in outdoor<br />
use along the water course. As a material, as well<br />
as providing superior protection <strong>from</strong> the weather,<br />
aluminium also offers greater fl exibility in the<br />
customised production of switchgear.<br />
ISAB Klitschmar GmbH manufactures industrial switchgear<br />
for pumping stations, which are either massproduced<br />
or supplied as customised units tailored to<br />
the customer’s individual requirements. The company<br />
specialises in control technology for the water and waste<br />
water sector, and produces a wide range of <strong>solutions</strong><br />
for pumping stations and sewage plants, ranging <strong>from</strong><br />
the simple to the highly complex. At the company’s<br />
headquarters in Wiedemar-Klischmar (Saxony), the team<br />
designs and plans switchgear, <strong>from</strong> new circuit diagrams
through to detailed optimisation of pre-existing designs.<br />
Rittal supplies the customised outdoor enclosures and<br />
accessory components for interior installation, such as<br />
compact enclosures, heaters, thermostats and enclosure<br />
lights.<br />
In the past, ISAB exclusively used fi breglass-reinforced<br />
enclosures, but in 2009 it increasingly switched to aluminium<br />
enclosures. This highly robust material is particularly<br />
convincing for outdoor use. “Aluminium withstands<br />
outdoor conditions much better than fi breglass – almost<br />
permanently, primarily because of its resistance to UV<br />
radiation”, explains Karsten Scharte, Managing Director<br />
of ISAB. “Another advantage of aluminium is its fl exibility.<br />
Enclosures in the required size may be built far more<br />
quickly, whereas plastic relies on a lengthy and expensive<br />
moulding process”. The Saxony-based switchgear manufacturers,<br />
who operate both in Germany and internationally,<br />
decided to work with Rittal for logistical reasons. The<br />
standard enclosure <strong>from</strong> ISAB, which is used to house<br />
around 80% of all pumps, is always in stock at Rittal’s<br />
distribution and logistics centre in Gera, and can be<br />
delivered to ISAB within one or two days. This, in turn,<br />
benefi ts the customer as well: If necessary, a simple<br />
Rittal supplies the customised outdoor enclosures and<br />
accessory components for interior installation.<br />
switchgear can be supplied and ready to use within just<br />
three days. The standard delivery time is three weeks.<br />
Everything fl ows<br />
The range of applications for switchgear in the water<br />
management industry are very diverse. The spectrum<br />
ranges <strong>from</strong> power supply utilities such as local authority<br />
water boards, to fountains in pedestrianised areas,<br />
through to a variety of industrial processes where water<br />
plays a decisive role. A range of instruments are needed<br />
to control volumes, measure fl owrates or regulate infl ow<br />
and outfl ow. Controller production and control technology<br />
ensure that the fl ow of groundwater, sewage and<br />
drinking water is uninterrupted. Depending on requirements,<br />
these may either be simple pumping stations or<br />
complex <strong>system</strong>s that control complex processes, such<br />
as proportional infl ow rates.<br />
In future, collaboration between ISAB and Rittal is set<br />
to become even more intensive. ISAB is thinking of<br />
ordering matching busbar <strong>system</strong>s <strong>from</strong> Rittal to complement<br />
the fl exible aluminium enclosures and various<br />
other components to protect the interior, fully in keeping<br />
with the <strong>system</strong> concept.<br />
In future, in addition to fl exible aluminium enclosures and<br />
various components to protect the interior, the company<br />
also plans to purchase matching busbar <strong>system</strong>s <strong>from</strong><br />
Rittal.
Rittal – The System.<br />
A unique value-added<br />
modular <strong>system</strong><br />
Individual requirements demand customised <strong>solutions</strong>. “Rittal – The System” ensures a uniform <strong>system</strong> platform<br />
worldwide. Our entire expertise is combined in a <strong>single</strong> <strong>system</strong> package, in a synthesis of products, engineering<br />
tools and services. Rittal supplies everything <strong>from</strong> a <strong>single</strong> <strong>source</strong>: Enclosure and case technology, effi cient<br />
climate control, power distribution and back-up. What is more, Rittal <strong>system</strong> consulting will advise you on<br />
how to maximise your investment in terms of cost and energy effi ciency.<br />
Engineering<br />
Cost minimisation with the planning, design and production of enclosures.<br />
RiCAD 3D component library: 3D data for effi cient mechanical design<br />
Planning software for low-voltage switchgear<br />
Climate calculation software for requirement-based cooling dimensioning<br />
Integration with the engineering tools <strong>from</strong> EPLAN<br />
Products<br />
TS 8 enclosures – the basis for <strong>system</strong> architecture, proven a million times over<br />
Modular enclosure technology for diverse applications<br />
Energy-saving cooling units<br />
Effi cient power distribution and back-up<br />
Weatherproof outdoor enclosures for outdoor use<br />
Comprehensive range of accessories<br />
High levels of fl exibility, fast assembly, global availability, tested quality<br />
Service<br />
Global 24h service and customer proximity with more than 60 subsidiaries<br />
and 40 international agents<br />
Planable costs with international maintenance contracts around the globe<br />
Extendible warranties
Satisfi ed customers are<br />
the best reference<br />
A Blumenbecker<br />
B Commerzbank<br />
C Heyligenstaedt<br />
D RWTH Aachen<br />
E F<br />
E Schering<br />
F Vakumix<br />
G Vion<br />
H Zentis<br />
A B
G H<br />
C D
Rittal – The System.<br />
Faster – better – worldwide.<br />
Rittal GmbH & Co. KG<br />
Postfach 1662 · D-35726 Herborn<br />
Telephone: +49(0)2772 505-0 · Telefax: +49(0)2772 505-2319<br />
eMail: info@rittal.de · www.rittal.com<br />
REFERENCE BROCHURE Industry<br />
05/2010 · E902