SMPS Enclosures EDR-75 for Automation Equipment

Service Process for Custom SMPS Enclosures (EDR-75) in Automation Equipment

1. Initial Consultation and Requirements Assessment

This initial phase is about understanding your precise needs. We'll delve into your automation equipment's specific requirements, including power demands, desired output voltage (EDR-75 offers 12V, 24V, 48V, etc.), available installation space (confirming if the EDR-75's slim 32mm width is suitable), operating environment temperature, and budget. Crucially, we'll discuss your specific custom enclosure requirements:

1) Mounting Method: Beyond standard DIN rail, are there needs for additional mounting holes or brackets?

2) Protection Rating (IP Code): Is a higher level of water or dust protection required?

3) Special Interfaces: Are extra wiring ports, indicator light holes, or fan openings needed?

4) Thermal Considerations: What are the internal heat distribution and heat dissipation needs of your equipment? Does it require special heatsinks or ventilation grille designs?

5) Material and Surface Treatment: Do you have specific material preferences (e.g., aluminum alloy, steel plate), surface treatments (e.g., powder coating, anodizing), or colors?

6) Branding Requirements: Do you need custom printing, silk-screening, or engraving of your logo or product information? We'll also analyze the industrial environment your equipment will operate in to determine any special environmental adaptability the custom enclosure needs (e.g., vibration resistance, corrosion resistance). Based on the EDR-75's dimensions and electrical characteristics, we'll assess the technical feasibility of the custom enclosure and provide initial design directions and suggestions.

2. Custom Design and Solution Confirmation

In this stage, we collect all detailed specifications related to the custom enclosure, including precise dimension drawings and 3D models (if available), along with interface layout diagrams. We will then proceed with the enclosure's structural design and create detailed 2D/3D engineering drawings (including assembly and part drawings). If necessary, we'll conduct thermal simulations or structural strength analyses to ensure the custom enclosure meets heat dissipation and mechanical strength requirements.

Prototype creation and sampling is a critical step here. We'll produce a physical sample of the custom enclosure for functional, fitment (with the EDR-75 and your equipment), and aesthetic verification. This allows for timely identification and correction of design flaws. We'll then conduct multiple design reviews with you, incorporating feedback until the final custom enclosure design is confirmed.

3. Production and Quality Control

Once the design is confirmed, we'll source the necessary materials and perform precision machining processes (such as CNC punching, bending, welding, CNC machining). This is followed by the required surface treatment processes like powder coating, anodizing, or plating. We'll also implement any specified branding, such as silk-screening or laser engraving. If the custom enclosure comprises multiple components, we'll handle the assembly.

Finally, a rigorous quality inspection will be conducted, including dimensional measurements, appearance checks, protection rating tests (e.g., IP testing), and assembly tests with the EDR-75, to ensure compliance with design requirements and quality standards.

4. Supply and Logistics

Your custom enclosures will be properly packaged to prevent damage during transit. We'll then coordinate the transportation, customs clearance (if international shipping is involved), and delivery, ensuring the products arrive safely and on time at your specified location. 

Common Materials in Producing Custom SMPS Enclosures EDR-75 for Automation Equipment

1) Steel:

Characteristics: High strength, relatively low cost. Often used when high strength is required but weight isn't the most critical factor. It might be galvanized (for enhanced corrosion resistance) or powder-coated.

2) Aluminum 5052:

Characteristics: good formability, corrosion resistance, and cost-effectiveness.

3) Aluminum 6061:

Characteristics: higher strength, better machinability, and the potential to integrate features like heatsinks through extrusion.

Considering the EDR-75's "slim" design and emphasis on "heat dissipation performance," aluminum alloy or surface-treated steel are the most probable material choices. Metal enclosures are also vital for the electromagnetic shielding of internal electronic components, effectively reducing electromagnetic interference.

Processing Characteristics of EDR-75 Enclosures

As a standardized industrial power supply, the EDR-75 enclosure typically exhibits the following processing characteristics:

1. Precision Sheet Metal Fabrication

This is the core process for manufacturing the thin-walled metal enclosures like the EDR-75.

1) Cutting:Laser Cutting or CNC Punching: Used for precise cutting of metal sheets to form the initial shape of the enclosure and create various openings (e.g., terminal holes, indicator light holes, ventilation holes, DIN rail mounting slots). Laser cutting allows for complex geometries and high precision, while CNC punching is suitable for standard hole patterns in high-volume production.

2) Bending/Forming:

CNC Press Brake: Precisely bends the cut metal sheets into the 3D shape of the enclosure according to design drawings. The EDR-75's ultra-slim design demands extremely high bending accuracy to ensure tight fit and aesthetics after assembly.

Welding or Other Joining Methods:

If the enclosure consists of multiple parts, spot welding, laser welding, or other joining techniques might be used to permanently connect them. However, for compact designs like the EDR-75, clever bending and snap-fit structures might be used to reduce welding, enhancing production efficiency and lowering costs.

2. Surface Treatment

To enhance the enclosure's protection, durability, and appearance:

1)Powder Coating: Common for steel enclosures, offering scratch resistance, corrosion resistance, insulation, and a variety of color options.

2)Anodizing: Common for aluminum alloy enclosures, enhancing surface hardness, corrosion resistance, and allowing for various colors. It also improves heat dissipation.

3)Galvanizing: Applied to steel, providing rust and corrosion protection.

3. Precision Dimensions & Tolerance Control

1) Narrow Width: The EDR-75's mere 32mm width requires extremely high dimensional accuracy in enclosure manufacturing to ensure smooth installation on DIN rails and maximize control cabinet space.

2) Fit with Internal Components: The enclosure must precisely match the dimensions and positions of the PCB boards, transformers, capacitors, and other internal components of the power supply to ensure secure and stable fixation.

4. Ventilation Hole Design

The enclosure will feature strategically placed ventilation holes or grilles to promote free air convection for internal components, ensuring the power supply operates stably within its specified temperature range. The shape and size of these holes are also achieved through precision manufacturing.

5. Marking & Information Printing

The enclosure surface will feature branding logos, model numbers, input/output parameters, safety warnings, and certification marks (e.g., UL, CE) printed via methods like silk-screening, laser engraving, or pad printing.

These processing materials and characteristics collectively ensure the EDR-75 enclosure's structural integrity, excellent heat dissipation performance, good electromagnetic compatibility, and the ability to operate reliably long-term in various industrial automation environments.

Why choose Waltay to produce custom SMPS Enclosures EDR-75?

1) Expertise in Industrial Power Solutions & Enclosures: We don't just supply metal parts; we understand the entire ecosystem of industrial power supplies and automation equipment. This means we know the specific demands of an EDR-75, including its thermal management requirements, mounting constraints, and the need for robust protection in industrial environments. Our deep knowledge ensures the custom enclosure not only fits perfectly but also enhances the performance and longevity of your power supply.

2) Specialized Material & Processing Knowledge: We are highly proficient in working with the ideal materials for SMPS enclosures, particularly 5052 and 6061 aluminum alloys.

If your priority is excellent formability, corrosion resistance, and cost-effectiveness for a standard-looking enclosure, we'll guide you towards 5052.

3) Comprehensive Customization & Design Support: Our service goes beyond just manufacturing. We offer end-to-end design support. We can even provide prototyping and sampling to ensure the design meets all your expectations before full-scale production.

4) Rigorous Quality Control: Quality is paramount, especially for components in automation equipment. Our manufacturing process includes strict quality checks at every stage, from material inspection to final assembly and finishing.

5) Reliable Supply Chain & Timely Delivery: We understand the importance of timely delivery to keep your production lines moving. We have established a robust supply chain for materials and manage our production schedules efficiently to ensure your custom EDR-75 enclosures are delivered on time, every time.

Waltay is specializing in custom CNC machined parts for over 15 years. We are good at making high precision metal and plastic components. We also provide one stop service such as part design, prototypes, mold making, plastic injection and part assembling to better meet customers’ needs. Beside aluminum CNC machined parts, we also provide stainless steel, ABS, PC, PA,PP and POM CNC machined parts which can be widely used in cables, sensors, motors,connectors, etc.