Power Distribution Panel

Mobile Power Distribution. A versatile and durable electrical panel system compatible with 120 VAC, 208 VAC, and 480/600 VAC panelboards. Supports MCCB breakers and features standardized glands for easy assembly, compatibility, and maintenance, ensuring reliable performance in industrial and commercial applications. 

Universal Design

The design was enhanced to accommodate a wide range of panelboards, including 120 VAC, 208 VAC, and 480/600 VAC configurations. Additionally, it was updated to support the mounting of MCCB (Molded Case Circuit Breaker) units, ensuring greater versatility and compatibility across various electrical systems.

Modular Glands

The input, output, and passthrough glands were standardized to ensure seamless product compatibility. This standardization simplified the assembly process, streamlined the ordering of replacement parts, and reduced the potential for errors during manufacturing and maintenance. 

Overview

I investigated the change from a Powder Coated Steel design to an Aluminium one.

The main reason for the investigation was to:

• Reduce Corrosion 

• Reduce Weight

• Reduce Cost

Corrosion Reduction

By using Marine Grade Aluminium, the risk of corrosion was significantly reduced. Unlike Powder Coated Steel, which can chip and expose the underlying material to rust, Aluminium naturally forms a protective oxide layer, improving durability and extending the product's lifespan in harsh environments. 

Weight Reduction

The transition from Powder Coated Steel to Aluminium reduced the weight of the product from approximately 180 lbs to 100 lbs, achieving a 45% weight reduction. This significant decrease not only improved handling safety by reducing the likelihood of strain or injury when moving the product but also made the design more ergonomic for end-users. 

Reduce Cost

While the cost of raw materials, forming, and welding Aluminium was comparable to that of Powder Coated Steel, the redesign provided savings in other areas:

• Elimination of Powder Coating: Marine Grade Aluminium does not require additional protective coatings, eliminating the time and expense associated with powder coating.

• Lower Shipping Costs: The reduced weight of the product decreased shipping expenses, especially for bulk transportation.

• Improved Storage and Handling: The lighter design made it easier to move and store, reducing labor effort and minimizing the risk of damage during these processes.

Impact Resistance

To combat the reduced tensile strength of Aluminium over Steel, the structural components were increased in thickness to ensure that the design did not experience a reduction in strength.

Outcome

The redesign successfully met the objectives of corrosion resistance, weight reduction, and indirect cost savings, making the product more durable, easier to handle, and cost-effective over its lifecycle.