As a core component of the power system, the manufacturing process of electrical control cabinets directly affects the safety and stability of equipment operation. Based on industry standards and production practices, this article systematically analyzes the key steps and technical requirements of the entire manufacturing process of control cabinets.

 

I. Requirement Analysis and Solution Design

The manufacturing process begins with the requirement analysis stage. It is necessary to clarify the power range of the controlled object, the operating environment (such as temperature, humidity, and corrosiveness), and the requirements for the protection level (IP54/IP65). Professional engineers use CAD software to complete the design of three drawings: the electrical schematic diagram determines the logical relationship of components, the layout diagram plans the spatial structure of the cabinet, and the wiring diagram guides the cable connection. In particular, it is necessary to select components such as circuit breakers and contactors according to the GB/T 14048 standard, and reserve 10 - 15% power redundancy to ensure long - term stable operation.

 

II. Cabinet Manufacturing and Material Processing

Cold - rolled steel sheets (thickness ≥ 1.5mm) or 304 stainless steel are the mainstream materials for cabinets. Laser cutting is used with an accuracy control of ±0.2mm. After bending and forming, argon arc welding is used to ensure the structural strength. The surface treatment adopts a three - coating and two - baking process: after degreasing and phosphating, epoxy primer is sprayed first, and then polyester topcoat is applied. Finally, the 60μm coating passes the 500 - hour salt spray test. For equipment with a transportation environment requirement of - 25°C to 55°C, the design of anti - freezing sealing strips and anti - seismic brackets needs to be added.

 

III. Component Installation and Process Control

A modular assembly mode is adopted. The verticality error of rail installation should be < 1.5‰. The wiring process follows the three - verification principle: verify the drawing against the physical object, the wire number against the terminal, and the phase sequence and polarity. Three types of potential hazards should be prevented:

1. The parallel spacing between strong and weak electrical lines should be > 150mm.

2. The bending radius of cables should be > 6 times the wire diameter.

3. The contact resistance at the copper busbar connection should be < 50μΩ.

 

IV. System Testing and Quality Verification

The assembled equipment must pass four - level inspections:

1. Insulation test: Measured with a 500V megohmmeter, the insulation resistance to ground should be > 100MΩ.

2. Withstand voltage test: No breakdown or discharge occurs at 2500V for 60s.

3. Function joint adjustment: Simulate 32 working conditions such as overload and short - circuit.

4. Load test: Continuous full - load operation for 72 hours.

 

V. Packaging and Transportation Technical Specifications

Sensitive components are wrapped with anti - static pearl cotton, and buffer corner codes are installed around the cabinet. The transportation temperature monitoring range is - 25°C to 70°C, and the vibration parameters are controlled within 5 - 200Hz/2.8Grms. The delivery materials should include three sets of technical documents: wiring diagram manuals, test reports, and 3D model files (in STEP format).

 

The entire manufacturing process needs to implement the IEC 61439 standard system. Three risk points should be closely monitored: electromagnetic compatibility calculation in the design stage, electrostatic protection in the assembly stage, and waveform harmonic analysis in the testing stage. By establishing a visual process kanban and a traceability system, the quality control of the product throughout its life cycle can be effectively guaranteed.