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Switch Cabinet Construction

Reduction of manufacturing costs and improved quality through customized levels of automation

The assembly of cables in switch cabinet construction is still mostly carried out completely without any support from automated machinery. Skilled specialists manually process the cable and wire the cabinet according to an electrical diagram, with cables being individually cut to length, stripped, crimped, marked and wired. This takes a lot of time. However, the assembly of cables in the construction of switch cabinets has an enormous potential for automation. Optimum solutions do exist, from semi-automatic assembly for the production of one-off units and small series to fully automated production in large-scale manufacturing.

> Find out more about switch cabinet construction automation in our video

Time is money – Consideration of timings

The conventional method of wiring a switch cabinet involves the use of pliers and tags and the reading of electrical diagrams. Of course this is a flexible way of working – if you have enough time!

With the traditional mode of operating you would need 105 seconds per cable. If the switch cabinet requires 500 cables, the employee would need 14.6 hours!

With suitable automation, the time per cable can be halved. Thonauer brings you the solutions you need. The prerequisite for this is that the wire lengths are known and inkjet printing is acceptable.

Depending on the solution approach and the type of production, automated cable processing can save up to 50 % compared to the current methods of operation. However, not only can a lot of time and money be saved in cable processing, but also in the wiring activity itself. 


State of the art cable processing

The basis for the optimized automation of cable assembly within control cabinets is the availability of electronic data such as cable length, marking and the processing of the cable ends. These data are converted from a wiring list to a cutting job, or even generated directly via an ECAD system. If the data are not available in electronic form, they can usually be conveniently programmed using machine software.

Data transfer from the ECAD to the machine


Sequence of the automatic production of complete wire harnesses

› Elimination of human input errors
› Changes can be made in a single system - the ECAD
› The cable marking always matches the definition in the diagram





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