As one of the leading electrical companies in the Kingdom of Saudi Arabia, Al Fanar Electric specialises in five production categories: power distribution and control, electrical switches and sockets, cables & wires, transformers and lighting solutions. Al Fanar has its own automation division to achieve top production quality, which develops modern production plants with a high degree of productivity and automation. One of the latest projects is to set up a production line for assembling miniature circuit breakers.
In a miniature circuit breaker there are essentially two components to be assembled: the so called
Homam Al Osman (left) as the representative of the Weidmüller engineering and sales team (to which Ibrahim Doumit also belongs) together with the Al Fanar automation team with u-remote in the background
“arc runner”, which detects the electrical arc caused by short circuit excess current, and the “blow out magnetic part”, which is responsible for thermal and magnetic tripping. The magnetic tripping device consists of a magnetic core, the coil and a moving contact. These items are connected together with a copper braid. In the Al Fanar factory, one of the production machines welds the moving contacts and the coil with the braid.
The deformation of the welded parts is checked using an analogue displacement sensor. In addition, an analogue proportional pneumatic valve is used to better control the welding head movement. Moreover, a number of digital proximity switches and alarms are used for precise process synchronisation and alerting.
In planning this process, the automation team of Al Fanar were faced with the challenges of little available space in the control cabinet, as well as the high data transmission speed.
u-remote – installed as part of the new Al Fanar production line
By virtue of its particularly space-saving modules and the compact 4-pole connectors for connecting sensors, Al Fanar was impressed by the remote I/O solution from Weidmüller. Using the network compatible Profibus DP coupler, the signals are recorded and transmitted via a Profibus DP environment to the main control unit (PLC). Using the UR20-FBC-PB-DP coupler module running at a baud rate of 1.5 Mbit/sec as the active component on the field bus ensures fast, reliable and fault-free mapping of digital and analogue field signals to the bus master. For Al Fanar this means a dependable production process for its miniature circuit breakers, which fully complies with the electrical company's performance standards.
Thanks to the intensive technical support from the
engineers and sales team of Weidmüller Middle East, Al Fanar found in u-remote an efficient and high-performance solution for recording and transmitting sensor signals.
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Published in July 2015