ELECTRICAL

PANEL BOARD
MANUFACTURING

SUB TITLES

1.

2.
3.
4.
5.
6.
7.

Manufacturing PRODUCT
SPECIFICATIONS
MACHINERY REQUIRED
Project layout
PROCESS
MACHINERY COSTING
MARKET ANALYSIS
BUSINESS CALCULCULATION

Manufacturing PRODUCT
SPECIFICATIONS :
TYPE:
Totally enclosed, dust and vermin proof, cubicle fixed Type
free standing, single/double front, air-insulated type for use in 600 Volts,
50Hz, Three Phase with neutral system. Fault level 50 kA RMS/1 Sec.
GENERAL CONSTRUCTION:

The panels will be designed, manufactured and tested in

accordance with the latest versions of the related applicable standards
and as per the drawings / specifications.

The panels will be of modular design with a horizontal bus bar

chamber running at the top and the cable entry will be from the bottom.
Individual vertical bus bars will be provided for feeding to the feeder
modules at the rear side of the feeder chamber. Complete metallic
partition sheets will be provided between any two adjacent vertical panels
or horizontal feeders.
The incomer chamber will be located at the extreme end. All
feeders chambers and the cable chamber will be provided with hinged
doors. For the bus bar chamber, the inspection covers will be of bolted
type. All of the electrical accessories will be mounted on the front side of
the panels. Suitable cable core clamping arrangement will be provided in
the cable alley / chamber. Each feeder compartment will be provided with
suitable nameplate showing the panel details like SFU/MCCB rating and
the Starter rating along with the nomenclature of the equipment
connected.

FABRICATION DETAILS:
An integral metal base channel of requested size will be
provided. All of the Gland plates will be of requested SWG CR sheet. The
gland plates will be suitable for fixing Siemens type single compression
glands as per the cable schedule. The doors will be provided with
neoprene gaskets. Requested SWG CR will be used for compartments
partitions inside the panel board. Suitable ventilation louvers will be
provided onto the vertical and horizontal bus bar chambers to facilitate
free circulation of air.
PAINTING:
All sheet steel parts will be subjected to a finishing process
known as 7 TANK PROCESS consisting of chemical degreasing,

pickling, phosphate by Chemical Washing and finally finished with powder

coating and baked in oven. The finishing will be elegant and enduring.

BUS BARS :
Three phase and neutral requested bus bars will be
provided. They will be of uniform cross section throughout the panel with
continuous current rating of 0.8 Amps/Sq mm for aluminium ,1.2
Amps/Sq mm for copper. The bus bar conductors will be supported by
tough, non-hygroscopic, resin bonded self extinguishing fire retardant
insulators of SMC / DMC type firmly fitted to the framework of the panel.
Cadmium coated fasteners will be used for the bus bar joints.Suitable
heat shrinking sleeves will be provided for the bus bar conductors with
colour coding.

All live parts will be shrouded with non-deteriorating

insulating barrier to prevent against accidental contact. Provision for

expansion with necessary hardware and fishplates will be provided onto
the Horizontal bus bar chamber at the top. Suitable ventilating louvers
will be provided in the bus bar chamber. These louvers will be provided
with brass mesh to prevent entry of vermin.

EARTHING:
AL. Earth Bus bars of required size will be provided
throughout the length of the panel.

Within the panel board, all the

switchgear bodies will be duly connected to the earth bus bars. Provision
for connection to the plant earth grid will be provided at both the ends of
the panel. All hinged doors with electrical accessories will be provided with
flexible copper earth connections.
WIRING

Wiring of the control circuits will be carried out with 1.5

Sq mm size of 660/1100V grade multi strand single core copper flexible
wires. All CT wiring will be carried out with 2.5 Sq mm wires. Inter
connections in the starter and SDF feeders up to 63 Amps rating will be
carried out with suitable rated copper conductor multi strand wires.
Above 63 Amps rating, Al. bus bars will be provided for interconnections.
All the control wires at the terminal block will be identified
properly by providing suitable number / letter ferrules. All the power wires
will be identified properly by providing suitable PVC color-coded sleeves.

Sample panel board

MACHINERY REQUIRED:

Shearing/Cutting machine CNC:

Technical Specifications of CNC Shearing Machine Item
Specifications
Model Mercury632
Maximum cutting thickness 6mm
Maximum cutting length 3200mm

Stroke per minutes 12 times

Cutting angle 1.5 Main motor power 7.5kw
Dimensions 3840*1610*1620mm Weight 6600kg

Bending machine CNC:

1.1 This machine adopts full steel welding structure,
vibration aging eliminate stress, good rigidity and high
strength, and keep high precision
1.2 The entire frame rigid good, the work is smooth, safe
and reliable, easy to operate

1.3 Introducing the principle of elastic mechanics to

effectively control deformation of the structure, so it can
obtain satisfactory bending member.
1.4ThemachineadoptsNanjingESTUNE10bendingmachinedispl
aysystem
2. Main Specifications
Pressure KN 800
Worktable length mm 4000
Distance between columns mm 3020
Slider travel mm 120
Max. open height of the slider and worktable
mm 380
Depth ofthroat mm 320
Main motor power kw 7.5kw
Axial piston pump 25MCY14-1B
Digital display NanjingESTUN E10
3. The main parts and structure of the machine 3.1 Slider
part: WC67Y-80/4000 hydraulic plate bending machine
adopts hydraulic drive, slider part consist of sliderhydrocylinder and mechanical stop dog fine-tuning structure.
Slider stroke length can be adjusted, does to the work piece
which do not need too long travel , adjusted by the
mechanical stop
Dog can significantly improve the work efficiency. Right and
left oil cylinder fixed on the frame, through the hydraulic
system to make the piston drives the sliding block moves up
and down. 3.2Worktableparts: There are three compensation
cylinders equipped on the work table riser, can achieve
better bending effect. Work table operate through the button
box in front of the work table to make the motor drive

retaining rack moves back and forth, and by digital display

mobile distance, there are travel switch limit position in both
before and after.
3.3 Back-gauge part: back-gauge part using motor to drive,
through the sprocket drive two screw synchronous moving,
counter displays the size of keep-off, can manual fine tuning.
3.4 Synchronizing system: This machines mechanical
synchronous mechanism is composed of torsion shaft and
swing arm , simple structure, stable and reliable
performance, high precision synchronous.
3.5Displaysystem: It is equipped with Nanjing ESTUN E10
bending machine display system:
X axis screw pitcherror self-compensating
X axis one-way positioning gap hint
X axis soft limitingfunction
Time relay function
Tally function
free setting scale factor
Power off memory location
Metric and inch system and so on function
4. Working environment
4.1 Working voltage: 380V50HZmagnitude of a voltage
fluctuation 10% 4.2
Environment temperature: 0+40
4.3 Relative humidity: 20-80%
4.4 Less dust, harmful and corrosive gas
4.5 Away from the strong earthquake and electromagnetic
interference.
5. Standard
5.1 GB/T14349-93 Sheet metal bendingmachine
precision 5.2 JB/10148-99Sheet metal bending
machine safety technique requirements 5.3 JBT2257.1-92

Sheet metal bending machine technical condition 6. Main

components standard configuration
6.1 Oil cylinder
6.2 Gear high pressure oil pump
6.3 Main electric: motor
6.4 Hydraulic valve
6.5 Sealing element Mould
6.7 Motor sliding
6.8 Display system
7. Surface treatment of machine. The under lying derusting
processing, paint uses high-grade polyurethane paint, if no
special requirement the colour is the manufacturer standard
colour.
8. Technical document Offer a full range of Chinese
instruction for use, safety operation manual, electrical
schematic diagram, machine tools, hydraulic principle
diagram
9. Acceptance standard as the customer requirements and
product accuracy according to the national institute of
standards and regulations.

Punching machine

Punching machine specifications

Functions
Punching Marking & Drilling
Max. size of workpiece (mm)
1500800
Max. diameter of punching (mm)
26
Plate thickness of punching (mm)
5~25
50
Max. diameter of drilling (mm)
Max. Thickness of drilling (mm)
40 mm
Punching force (KN)
1000
Marking force (KN)
800
Min. distance between hole and plate edge (mm
)
25
Dimensions of marking characters
14X10X19 (by customers' request)
Quantity of characters
10
Die-stations
3.00
Precision
+/-0.5mm
Input by keyboard, RS232 & USB interfac
Programming mode
e
Overall dimensions(m)
3.231.9/2.6
Weight (Kg)
8000.00

Steel sheet to channel roller:

STEEL SHEET TO CHANNEL ROLLER

FUNCTIONS
ROLLING,BENDING,MARKING
Dimensions
of workpiece (mm)
200 mm
Number of formatios
Upto 4
Sheet thickness for roll
2 mm
Rolling speed
12m/min
Type of material
Steel G235
Bending force (KN)
500 KN
Marking force (KN)
45 KN/station
Die-stations
13.00
Precision
+/-0.5mm
Hydralic pressure
2 bar
Overall dimensions(m)
0.8 X1.5 X5
Total weght of machine(kg)
5000.00

Automated powder coating system:

Pre treatment equipment of powder coating line

Paint Spray Booth

Curing oven and drying oven

Automatic Spraying and Reciprocating Engine

Powder Recovery Equipment

Paint spray gun

Shot blasting machine

Pre treatment equipment of powder coating line:

Dipping trench 1: Degreasing Dipping trench will be of 6000mm
length X4000mm breadth X1500mm height
Dipping trench 2: Phosphating trench will be of 6000mm length
X4000mm breadth X1500mm height
Dipping trench 3: Rinsing Dipping trench will be of 6000mm length
X4000mm breadth X1500mm height
Acid Filtration unit: acid filtration unit with motor pump, filter
required pipes
Motorised cleaning brush 1,2: rotating brush steel wired for cleaning
rust after dipping with 0.75 bhp
Paint Spray Booth:

Work piece transfer system:

Work piece transfer system connected to entire machines upto

storage ,working area,store.

Electrical fixures:
Required Electrical panels, Transformer, Cables, wires, lighting

system, etc.
Machinery civil works:
Required civil basement for placing machinery and shed flooring

Labour & positioning:

Required labour for positioning the machinery, cranes and hoists for
placing machinery
Other equipments:
Welding machines
Hand grinding machines
Hole saw cutters
Die set cutters
Chipping tools
Self drilling screw machines
Channel cutting machines
Hand tools sets

Layout:

PROCESS:

Cutting section:
All the loaded CI sheets are sheared as per requirement in
cutting section for channels doors and closures as per the
dimensions and sizes of the work jobs

Bending section:
All the sheared sheets are made into channels and doors,
partitions as per the given work job.
Powder coating section:
Bended channels, doors, partitions are washed in 7 processes
consisting of chemical degreasing, pickling, phosphate by Chemical
Washing and finally finished with powder coating.
Fixing section:
After baked in oven all materials come into fixing section where
all channels, doors, partitions are fixed and final switchgear fixing is
completed and sent to packing section.
Packing section:
All panels are packed for safe transportation
Shed :
Totally constructed shed with dim 15 m x 30 m for placing the
machinery,15 m x 30 m for storage

MACHINERY COSTING:

SL
NO
1
2
3

MACHINERY
SPECIFICATION
CUTTING MACHINE CNC OPERATED
BENDING MACHINE CNC
OPERATED/CHANNEL MAKER
POWDER COATING CONTAINER

AMOUN
T IN
LACS
26
36
75

4
5
6
7

ELECTRICALLY HEATED
ELECTRICAL FIXURES,ITEMS
MACHINERY POSITIONING,BASEMENTS
CIVIL BEAMS,WORK
OTHER EQUIPMENT

SHED COSTING

TOTAL COST

15
8
4
10
6

180

MARKET ANALYSIS:

Total consumption of panel boards in Andhra Pradesh was

estimated at 800 lacs per month which excludes distribution boxes

and for meter boards it was estimated to be 360 lacs the
apartments are growing day by day as per development of cities
from time to time. Under the construction of capitol for AP state a
estimate states 20000 registered offices are being shifted from old
capitol which require adequate infrastructure and facilities.
More than 200 panel manufacturers are available in Andhra Pradesh
where no mass production of panels is not available up to now. An
automation of panel building unit makes more number of panels
made under one roof which makes transportation cost very low as
compared to individual semi automated panel building units.
Enclosures for switchgear, distribution boards and washer making
can be done as by products.