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Even if keywords such as "embedded systems" and "IPC" dominate the switching systems forums, electrical connection technology remains the basis for a reliable controller. 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. Here, Fischer relies on WAGO rail-mounted terminal blocks and connectors.
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. 6.4 mm raw sheets run at up to 80 m/min through the angle cutters, they are positioned precisely to 0.05 mm, and cut in a little less than one second, from stamp-sized pieces to 1.5 m2 sheets. The CNC-controlled 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, Director of Electrical Assembly at Fischer, remembers "we had made service flights to Asia due to loose clamping points. Since the end of the 1990s, we use WAGO terminals. Thus such problems were eliminated. Although some customers were somewhat skeptical about spring clamp terminal blocks they soon changed their minds. WAGO is now practically our standard material." Uwe Thurn knows materials, for a good portion of the controllers are produced directly at Fischer. Outside companies are only contracted for control cabinet construction when bottlenecks occur. Here the entire spectrum of their rail-mounted terminal blocks are used, starting with the 33.5 mm long 2-conductor 870 Series terminal on through to the "95ers," currently the only spring pressure terminal for conductor 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. Thus the signal separation required for the CNC controller connection is done with terminals 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 way, we can easily convince them of the good quality of our products."
Connectors from the WAGO range are also used. The boards in the control consoles are equipped with the MULTI CONNECTION SYSTEM (MCS). Other systems that were used prior to this could not stand up to the ambient conditions that were prevalent.
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