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In the run-up to the market launch, we conducted a field test together with Hanseatic Power Solutions GmbH (HPS for short) to determine the actual productivity benefits during the wiring process.
HPS designs and manufactures switchgear and control systems for a wide range of sectors – including industrial, building, marine and off-shore applications. The company’s portfolio ranges from simple emergency power supply control equipment to complete electrical systems for power stations.
HPS, which is based in northern Germany, employs 85 people, operates worldwide and also has a branch in Abu Dhabi. To date, the company has been using various products from Eaton's portfolio, such as the PKZ and PKE motor-protective circuit breakers with screw terminals and the DIL A and DIL M contactors with screw and spring-loaded terminals. For the wiring of these switching devices and accessories alone, four different torques need to be taken into account.
Mr. Mähnss, what was your motivation to take part in this test?
We have been using Eaton devices since 2009, initially those with conventional screw technology, then partly switching to cage clamps and finally to Push-in technology. At first, we only used Push-in connections for terminal blocks, but then we added more and more devices. Now we are about to make the switch for Eaton contactors as well. The test gave us the opportunity to find out in advance how much time we can really save with Push-in technology during production.
Is time a critical factor for you?
Of course! The longer it takes our employees to wire the switchgear, the more expensive it becomes. And the easier we make the wiring work for our staff, the faster we can deliver the system. Every minute, every hour is money.
What are the most important results of the test for you?
Compared to screw terminals, we were able to demonstrate average time savings of around 50 percent for Push-in connections. What surprised us, however, was the time saved in comparison with spring-loaded terminals, where we also identified considerable time savings of around 40 %.
That's actually quite a lot, given that spring-loaded terminals are already considered a more efficient connection technology. How do you explain these time savings?
The explanation is relatively simple: In the case of spring-loaded terminals, opening the connection requires a slotted screwdriver. This means that I have to hold the conductor in one hand, and the tool needed to connect it in the other. With Push-in technology, I don't need any tools, enabling me to hold several conductors in one hand at the same time, which I can then plug in one after the other using the other hand – which saves a lot of time.
Apart from these time savings, what other advantages do Push-in connections offer?
For one, they provide greater safety during wiring: Especially when connecting larger devices, selecting the right torque for the screw terminals can be a problem. If the selected torque is too low, fires may easily occur during live operation. During testing, these errors are not necessarily noticeable due to the low test current, but if the terminal is subjected to the maximum current during operation, it may burn to a crisp. Push-in terminals completely eliminate this risk. With Push-in terminals, there is also no longer the risk of excessive torque, meaning there is no danger of the screw head being torn off.
Is it fair to say then that the significantly greater efficiency of the wiring process also helps to combat the shortage of skilled workers?
That is indeed the case. In the course of digitalization, the workload is shifting away from purely manual tasks such as wiring to new technologies such as the creation of digital twins, the routing of cables via software, and so on. If our well-trained staff needs less time to wire the systems by using the tested Push-in technology, we can invest more time in the preparatory work, which in the end means quality improvements thanks to better planning.
If you now replace all devices equipped with screw terminals with Push-in products – what efficiency gains will that bring?
We have already been using Push-in terminal blocks and control relays for some time. In combination with prefabricated cable harnesses, which are labeled with the target designation, we can achieve time savings of up to 50 % during assembly and wiring.
What is the level of acceptance of Push-in technology across different industries - are there any reservations?
No, there aren’t. We also use Push-in connections in marine technology, for example. Most companies and certification bodies have no problems with Push-in technology.
In your experience, how does Push-in technology perform in terms of vibration resistance?
Until now, our switchgear with Push-in connections has never come loose, not even during shipping. Even though customers should always check all connections prior to commissioning, regardless of whether Push-in or screw terminals are used, the risk of any parts coming loose during transport is much lower with Push-in terminals.
Does this mean that you will soon be switching completely to Push-in technology?
That's right, as soon as the Eaton devices with Push-in connections come onto the market – which is currently planned for summer 2021 – we will implement the change.
