Time, material savings mean cost savings

Below is an example of how saving time and money on materials can translate to overall savings when wiring wire motor starters, contactors, and pilot devices.

08/13/2013


Many people say, “Time is money.” However, material is too. When it comes to engineering, assembling, and testing control panels, reducing either time or materials (or both) can reduce costs significantly. Here are two examples that illustrate how reducing time and materials can also reduce costs. 

In the time reduction example, the estimated time to wire motor starters, contactors, and pilot devices is 4 hours and 29 minutes. However, the estimate is only 41 minutes if a device-level wiring system is used—an 85% reduction in wiring time. Engineering and testing times were also reduced.

Courtesy: Eaton

In the material reduction example, an installation that consisted of 1,600 motor starters would have required 7.83 miles of control wiring. However, by using a device-level wiring system, only 0.45 mile of flat cable was used. Calculating the material cost of each method using $0.61/ft for flat cable and $0.14 for #14 AWG, the device-level wiring system saved more than $4,300. In addition, the calculated savings for wiring/assembly time was 22 man-days.

Courtesy: Eaton

Another significant benefit is the device-level wiring network allowed the system to be installed and commissioned without having to ring out a multitude of control wiring connections. This type of control system can also connect electronic motor starters to the system, which allows motor current and other loads to be monitored without having to add current transformers or analog input cards to the PLC. This feature could enable a higher level of predictive data monitoring that was prohibitively expensive in the past.

This article appears in the Applied Automation supplement for Control Engineering and Plant Engineering



No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
Control Engineering Leaders Under 40 identifies and gives recognition to young engineers who...
Learn more about methods used to ensure that the integration between the safety system and the process control...
Adding industrial toughness and reliability to Ethernet eGuide
Technological advances like multiple-in-multiple-out (MIMO) transmitting and receiving
Virtualization advice: 4 ways splitting servers can help manufacturing; Efficient motion controls; Fill the brain drain; Learn from the HART Plant of the Year
Two sides to process safety: Combining human and technical factors in your program; Preparing HMI graphics for migrations; Mechatronics and safety; Engineers' Choice Awards
Detecting security breaches: Forensic invenstigations depend on knowing your networks inside and out; Wireless workers; Opening robotic control; Product exclusive: Robust encoders
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
News and comments from Control Engineering process industries editor, Peter Welander.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
Anthony Baker is a fictitious aggregation of experts from Callisto Integration, providing manufacturing consulting and systems integration.
Integrator Guide

Integrator Guide

Search the online Automation Integrator Guide
 

Create New Listing

Visit the System Integrators page to view past winners of Control Engineering's System Integrator of the Year Award and learn how to enter the competition. You will also find more information on system integrators and Control System Integrators Association.

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.