In the automation and controls integrator industry, quality has to be a top priority. In many cases control panel systems provide the critical administration capabilities necessary to manage the overall effectiveness of an automated system. For this reason a strict approach to engineering, design and control panel assembly should be followed to insure success with your panel build.
When designing a control panel there are many components that can make up the panel build such as; the enclosure, programmable logic controllers (PLC), power supplies, transformers, motor starters, contactors, fuse blocks, relays, circuit breakers, selector switches, motor starters, wiring, wire mounts and more. In this article we’ll discuss a six-step quality control method, which can be used to improve the quality of your control panel assembly.
Mechanical Inspection Process
Well documented drawings should accompany all required elements of the panel build to insure the control panel assembly process matches the engineered specifications. This procedure is part of the mechanical inspection process. During the mechanical inspection process an overall mechanical assembly should be reviewed for internal and external component locations, paint colors, legend plates, warning tags, device inspection, safety devices and secure device mounting. A quality control inspection form should be used to document your findings.
Electrical Inspection Process
The electrical inspection process is a critical component for control panel builds because it helps insure the control panel is wired correctly to specifications. During this phase of the quality control review fuses, circuit breakers, overload devices, suppressors, safety devices, relay coils and timers are inspected for location, type and value. Inspect wiring points for loose connections. PLC rack assembly, power supplies and dip switch settings are inspected for location and voltage usage, while an OHM meter is used to ring out all ground points and circuits. Each data point should be documented and tracked using the quality control inspection form.
Initial Power Test
Once the mechanical and electrical inspections are complete and the control panel meets the desired specifications an initial power test can be performed. To perform this test the control panel should be grounded, and the circuits disabled to apply the correct source voltage. This allows for testing of the whole range of circuit functions, while enabling control circuits as needed. All power devices that can be tested safely should be tested to check output voltages and any dysfunctional items should be noted in the quality control form.
Air Component Test
The next step is to test all air components. Gauges should be inspected for their correct value, air circuits should be inspected for the correct direction of air flow and tubing size and regulators should be adjusted for downstream pressure. The entire system should be inspected for air leaks and each solenoid valve should be checked for correct operation. Note any dysfunctional items on the quality control form with a description of the problem and indicate all devices which were rung out, powered, passed or failed and the type of repair needed.
Final Power Test
Once the control panel meets the specified requirements for operation an engineer overseeing the project should download the program and perform functional testing of the inputs, outputs, communications, operator interface and servo drive units, if the motors are available.
Final Assembly
Final assembly of the control panel will consist of inspecting wiring points for loose connections, installing any components which weren’t mounted, all previously identified issues resolved and acknowledged and then vacuumed and photographed. All actions and back ordered items should be documented on the shipping list and all original quality control forms filed in the Q.C. department. Modifications to the original drawings should be sent to the CAD department for revision updates.
Control panel assemblies can provide a wide range of benefits for companies looking to automate their business processes. However a stringent quality control process should be in place, along with quality suppliers to insure your panel build functions correctly and that it provides many years of great service. Working with an automation controls integrator that has a quality control methodology in place will streamline your control panel assembly and insure your project meets your required specifications.
1.can i have some list of materials,that a mechanical quality control have? 2.job descriptions? 3.rifinery plant rules and regulatoins..,thanks,more power and GOD bless!!
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Modifications to the original drawings should be sent to the CAD department for revision updates.
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Nancy.R
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