The control cabinet of the future: safe, efficient & intelligent

The need for climate-friendly energy generation and reliable distribution has never been greater. The range of requirements is becoming more and more comprehensive: it is important to generate energy as cleanly as possible, to act independently, to rely on renewable sources and to make distribution efficient and thus sustainable. In order to meet these high requirements, companies are increasingly relying on digitised components.

As the criteria change over time, adaptability and innovation are essential qualities for companies operating in this field. One example of this is Wöhner, based in Rödental in Upper Franconia.

The traditional family-owned company is continuously expanding its portfolio of electromechanical solutions and today has a wide range of electronic and digitised products. In doing so, Wöhner is guided by the aspiration to continuously increase the efficiency of its products and increase the added value for the customer.

Wöhner sees digitalisation and the associated new opportunities along the value chain as a 'toolbox' with which innovation leadership can be further expanded.


Compact designs save resources

In times of scarce resources and interrupted supply chains, careful handling of materials is essential. The state-of-the-art control cabinet solutions from Wöhner meet these requirements, for example through a high level of vertical integration, reduced use of plastic and durable, custom-fit components.

This is also the case with the CrossBoard: Due to its specific design, the CrossBoard is particularly space-saving and clear. If necessary, it can be easily converted and adapted to new requirements. With the integrated contact protection, it is also particularly safe – and it offers maximum flexibility in the control cabinet thanks to different lengths.

The CrossBoard combines all the advantages of a high-performance busbar system with traditional wiring on the DIN rail. Regardless of the technical refinements, the out-of-the-box solution can be assembled and equipped with components immediately after delivery, saving time and money. The assembly itself is also easy and completely without tools, not only during assembly, but also during the installation of the components.


Electronic components increase reliability

In the development of the MOTUS C14, Wöhner used an electronic solution for a motor starter for the first time and integrated the revolutionary C14 technology. In the event of a malfunction, the fuseless, reswitchable short-circuit protection switches off 100 to 1000 times faster than a conventional fuse or circuit breaker. As a result, plant consulting can be significantly reduced and the machine environment can be protected. In addition, this product also allows considerable space savings – and has integrated communication and measurement technology as well as an interactive and intuitive operating concept. The MOTUS C14 measures current, voltage and various performance parameters and allows conclusions to be drawn about the motor condition via the phase angle.


Smart applications for the digitised control cabinet

Not all components in the control cabinet are smart yet – but there is no way around data-driven and thus intelligent optimisation for greater efficiency and sustainable use of resources. Here, it is worthwhile to retrofit state-of-the-art functions: For example, the CrossMT measurement technology module from Wöhner makes the CrossBoard digital. The CrossMT is inserted between the busbar and the attachment and forms a kind of digital and intelligent intermediate layer between the two elements. By means of a feature upgrade, the range of functions is extended according to the application and the CrossMT is used in a tailor-made way.

In combination with various applications, the CrossMT module adds intelligent functions and connectivity wherever components in the control cabinet do not have them by default. It measures current, voltage and temperature and calculates quantities to be derived from this, such as power, energy, phase angle and frequency. This data can be transmitted via various communication interfaces such as USB-C, digital inputs/outputs or IO-Link. Status LEDs on the top and bottom of the device make it easier to keep track of things.

Solutions such as these have proven their worth for central tasks in the control cabinet, including the measurement of feed-ins to determine power quality, grid stability and energy consumption, but also for measuring at a safe outlet for fuse monitoring. In conjunction with a motor circuit breaker, motor parameters such as phase angle, harmonic content or residual currents can also be determined and conclusions can be drawn about the motor condition: an important prerequisite for predictive maintenance.


Data-based optimisations: measurement and analysis modules for a comprehensive overview

Only if vulnerabilities are detected directly and losses are uncovered can users take countermeasures. With increasing digitalisation, the collection and evaluation of data in the control cabinet is therefore becoming increasingly important. Monitoring modules ensure a comprehensive overview at all times and thus increase transparency in the control cabinet. They are the collection point for all data, evaluate it and pass on the analyses. Specifically, this includes multifunctional measuring devices for measuring current, voltage, power, energy and derived quantities. So-called power analysers also monitor the voltage and power quality, communicate via standard interfaces and show the important parameters and values directly via a colour display. Thanks to extensive evaluation options and the integrated storage system, they enable holistic energy management.

The MIEZ measurement and monitoring modules from Wöhner offer a holistic solution from measurement at central points to monitoring of the entire control cabinet with the mapping of the entire measurement chain. The products in this range are installed on the DIN rail or directly in the control cabinet door. In addition, they can be integrated into all Wöhner basic systems through the use of adapters. Commissioning and configuration is carried out via the application software on the PC or device.

Current transformers in conventional designs, i.e. 5 A, 1 A, or 333 mV on the secondary side, provide the current values in the application. The connection to the CrossMT or the MOTUS C14 will be possible in the future. It is operated via PC or defined buttons on the device, and clear displays guide you through the menu. The modules can communicate via Ethernet, RS485 and USB interfaces on the front of the device. Internal connections can be made via a separate standard – for minimal wiring effort.