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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

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