We explain everything about the production and properties of our industrial enclosures. In the enclosure wiki of ROSE Systemtechnik you will get the basic knowledge about materials, processes, protection types and much more.
The term “manufacturing processes” is generally used to summarise all manufacturing possibilities for workpieces. According to DIN 8580, manufacturing processes can be classified into six groups: Forming, forming, cutting, joining, coating and changing material properties (e.g. by heat treatment or conditioning).
ROSE Systemtechnik uses the term exclusively to describe the original forming possibilities of industrial, operating and display enclosures, i.e. the forming of moulds from shapeless materials. We use a total of six manufacturing processes to produce enclosures: Aluminium die casting, aluminium chill casting, polyester impact extrusion, plastic injection moulding, profile pressing and sheet metal bending / cutting / welding. Each process has an effect on the nature of the enclosures, which is why they have different properties with different production and fulfil different requirements in each case.
Aluminium die casting is a manufacturing process in the category of primary moulds according to DIN 8580. In this process, aluminium is heated to 580°C to 660°C so that the consistency becomes viscous. This liquid material is then pressed under high pressure into a mould, which consists of two steel parts.
The two-part mould can be opened and closed by moving machine plates and guide pistons. The cavity of the closed mould is called the “cavity”, which ultimately forms the shape of the housing. To fill the cavity under pressure, all the liquid aluminium is first poured slowly into a pressing chamber and pushed to the stop by a piston until all the air has been displaced.
To exclude the possibility of air remaining in the desired mould, there are special cavities (overflow) into which the air is displaced. The excess aluminium is sawn off and sanded after the casting process. Nevertheless, the quantity must be dosed appropriately, as an excess would cause the steel mould to burst and too tight a measurement would result in a mould that is not completely filled.
The piston then presses the liquid aluminium abruptly into the cavity. The hydrodynamic pressure created by the flow speed fills the mould completely. The pressure in the chamber is maintained until the aluminium has cooled down completely.
Since pure aluminium is not robust enough as a material for industrial enclosures, it is mixed with other materials such as manganese, magnesium or zinc to create an aluminium alloy (see alloys). The mixing ratio depends on the desired physical and mechanical properties. However, the main component is aluminium.
The advantage of this process is that the surface has a very high quality, fine contours can be cast, the production of the castings is cheap and the process can be fully automated. However, this requires high quantities, because depending on the size of the enclosure, a tool is only worthwhile from an order size of 3000 to 4000 pieces per year. ROSE Systemtechnik has these made according to customer requirements.
In this process, the liquid aluminium alloy is poured into a mould to harden at the edge. An ingot mould is a cast-iron reusable mould that consists of two parts. These can be opened up and together form a cavity that is closed on at least three sides, giving the shape of the aluminium casing. In addition, pins can be inserted into the cavities to form further shapes within the casting. These are also called pins or cores. Finally, the mould can be filled via an opening.
A distinction is made between inverted casting and low-pressure casting. In the first casting method, the melt is poured in via an upper open side of the mould and then hardens only at the edge. The still liquid core in the middle is poured back. In low-pressure casting, on the other hand, a mould that is open at the bottom is located above a bath of liquid aluminium alloy. The bath and the opening of the mould are connected by a riser pipe. A pressurised medium is fed in and pushes the melt up the riser tube into the mould. In this process, too, the aluminium hardens on the walls, the rest flows back into the bath.
Permanent moulds are particularly sustainable as casting moulds because they can be reused thousands of times. They are characterised by a high melting point, temperature resistance and resilience as well as good thermal conductivity. A protective layer of graphite and quartz powder surrounds the mould and prevents the liquid material from bonding with the mould. Otherwise, the hardened base housing would not be able to be released afterwards.
The advantage of this process is that larger castings with a high static load capacity can be produced. Nevertheless, small quantities can also be produced, but not fully automated, which leads to higher costs. A disadvantage is that fine shapes and smooth surfaces cannot be implemented due to the low pressure.
ROSE Systemtechnik also has moulds made for individual special enclosures at the customer’s request. However, due to manufacturing costs, we only offer this from a minimum order quantity of enclosures.
The following alloys are used at ROSE Systemtechnik:
AlSi9Cu3(Fe): Aluminium (main component), silicon (8 – 11 %), copper (2 – 4 %), iron (≤ 1.3 %)
AlSi12Cu1(Fe): Aluminium (main component), silicon (10.5 – 13.5 %), copper (0.7 – 1.2 %), iron (≤ 1.3 %)
AlSi12(Fe): Aluminium (main component), silicon (12 %)
AlSi10Mg(Cu): Aluminium (main component), silicon (10 %), manganese
Impact extrusion describes the production process for manufacturing products from polyester. The material we use is an SMC (Sheet Molding Compound). This is a sheet moulding resin with a high glass fibre content. The glass fibres in the SMC are long and ordered, which gives the end product a high strength. Moreover, since the polyester used is a thermosetting material, end products are dimensionally stable even under high temperatures.
To form or press the plate into a housing, a tool with two mould halves is used. It consists of a stationary die, whose inner shape gives the outer shape of the housing, and a movable punch that presses the polyester sheet into the die. The cavity of the two mould halves forms the housing.
The actual polyester material is cut from a roll to fit. The material is then folded and placed between the die and the punch. Material inserts such as bushings are also placed on the designated areas. Due to these steps, the production is associated with a manual effort.
The mould is now closed under high pressure (up to 450 tonnes). The already preheated mould halves are now additionally heated to facilitate the flow of the polyester resin. In order for the material and the glass fibres to spread evenly everywhere, the mould must remain closed for a few minutes. The time varies depending on the size of the enclosure.
After a few minutes, the tool half is opened again and the finished casing part is removed. Any protruding material must be removed with a knife, after which the housing part is finished.
Analogous to the die-casting process, the mould for the housing in the plastic injection moulding process also consists of at least two parts that are closed or opened via guide rails. The mould forms the negative of the actual workpiece. The cavity between the mould parts is filled with the plastic.
For this purpose, plastic granulate is gradually melted in a tapered cylinder and transported forward into the tip of the cylinder by an integrated screw conveyor. As soon as the injection mould contains sufficient homogeneous melt, the rotation of the screw conveyor stops and the injection unit is positioned at the opening of the mould to be filled. The screw conveyor is finally pressed towards the tip with high pressure to force the liquid plastic into the mould.
In order to optimise the material flow and the shape of the casting, it is important that the material cools down evenly and not too quickly. Therefore, in addition to the material thickness and mould slopes, channels are precisely calculated beforehand and laid in the mould, which heat the mould and the material during injection and enable targeted cooling.
After the material has cooled and solidified, the tool can be opened again and the workpiece removed. As this is a fully automated process, the production is only worthwhile for large quantities of around 5000 – 10000 pieces per year, depending on the size of the component.
Profile extrusion is a process for producing shaped metal parts by deforming metal rods or profiles under high pressure. It is also called extrusion, as the blank is usually a strand that is forced through a die (negative mould) to obtain the desired shape.
The profile pressing process is as follows:
Profile pressing is a fast and cost-effective process with high accuracy. It is often used in the production of architectural and industrial products such as window and door profiles, ladders, railings, automotive parts, structures for mechanical engineering and many other applications. At ROSE Systemtechnik, such profiles are produced for the HMI sector or for electronics housings.
In general, the term “sheet metal” covers flat-shaped metals with a height less than their length and width. Sheet metal is often characterised by being light, thin, strong and elastic. The processing methods include
ROSE Systemtechnik processes sheets of stainless steel to produce enclosures. The following stainless steel materials are used for this purpose:
The sheet metal is usually cut to size using a laser. The dimensions of the original sheet at ROSE are 1250 mm x 2500 mm. Larger cuts are therefore not possible. The usual material thicknesses for stainless steel enclosures are between 1.25 mm and 1.5 mm. However, material thicknesses of 2 mm and 3 mm can also be processed on request. The appropriate thickness depends on the size and the requirements of the desired enclosure. The cutting process also includes the laser cutting of cut-outs.
Another step in sheet metal processing is the integration of built-in parts (weld studs, press-fit studs) that do not interfere with the bending process. Welding studs are positioned on the sheet metal for this purpose. A high current creates a short circuit that melts the material under the stud and fuses the materials together.
To integrate press-fit bolts, suitable holes are lasered into the sheet metal depending on the type and size of the bolt. The bolt is inserted through the hole from above. However, the bolt has a collar that is larger than the cut-out and thus rests on the sheet metal. Now the bolt is pressed onto the sheet metal with high pressure. The special shape of the collar displaces the material and connects positively with the sheet metal.
Then the bending is done like bending punch and die, which are suitable for the length and the material thickness. The term “bending” describes a bending process in which the edges of a sheet are bent over towards the opposite edge of the sheet without thermal influence.
After completion of all bends, the welding process takes place. This depends on the length of the weld seam and the desired finish. A distinction is made between manual welding, machine welding and laser welding. The welds are cooled and formed with appropriate tools. During forming, a protective gas is introduced, which protects the weld seam from oxygen penetration.
ROSE Systemtechnik uses the following welding processes:
After welding has been completed, the remaining fixtures are mounted. For example, press-fit bolts and bushes, rivets and welding studs are inserted that were not previously fitted. In addition, components such as brackets are inserted into the enclosure by spot welding (resistance welding).
The surface of the enclosure is then prepared by brushing or sanding. Usually, a 240 to 320 grit is used for sanding.
To make enclosures resistant to external influences and visually appealing, we use various coating processes depending on the area of application. These include passivation, powder coating, wet painting as well as seawater-resistant wet painting and vapour deposition or finishing.
However, in order to prepare metal or plastic enclosures for surface finishing, a suitable pre-treatment of the surface is required, which is carried out in several steps:
The enclosure surfaces are prepared with a belt sander. The sanding of the enclosure surface serves on the one hand to improve the appearance and on the other hand as preparation for special processes such as screen printing.
These techniques are used to repair air holes created during the casting process and exposed during machining.
In our pre-treatment facilities, the enclosures are cleaned in a phosphate solution to remove machining residues such as coolants and lubricants. The phosphate layer improves the corrosion protection and the adhesion of the coating.
To ensure that the finishing process runs smoothly, we carry out strict checks to ensure optimum adhesion of the paint to the substrate. For this purpose, cross-cut test, salt spray test or measurement of the layer thickness are made.
As a final step in paint preparation, we tape the enclosures individually according to customer specifications in order to keep desired areas free of paint.
Passivation is a surface treatment to prevent oxygen corrosion. Passivation is only carried out on customer request and is only possible from a chromium content of 12% of the alloy. ROSE Systemtechnik uses chromium(VI)-free coatings < 0.5 μm. For this purpose, chromium(III) oxide is applied, which reduces the iron parts on the surface and thus allows the chromium parts of the alloy to oxidise. This oxide layer separates the metal from the atmosphere so that further corrosion is stopped.
The powder coating of our metal enclosures uses an electrostatic process in which the positively charged powder particles are deposited on the negatively charged surface and adhere. Powder coatings are based on epoxy or polyester resin. After the powder particles adhere, the coated enclosure is heated to at least 50 °C so that the resins melt and stick together. The advantages of this type of coating are that the overspray of powder coatings can be reused, the surface becomes particularly corrosion-resistant as well as mechanically resistant and the process is also particularly fast and environmentally friendly.
ROSE Systemtechnik offers a variety of different colours in different structures and different degrees of gloss to enable individual design wishes (such as: RAL, NCS, Pantone, etc.).
A low-viscosity lacquer is applied to the surface of the enclosure with a spray gun. In this process, the lacquer is mixed with a binder only immediately before application, which allows the lacquer to cure through a chemical bond (two-component lacquer). The advantage of wet painting is that it is easy to touch up and requires little energy for curing. In addition, wet paints can be used to create special effects and mix colours. The structure can also be influenced. In order to achieve an optimal result and to be able to guarantee a particularly high quality, ROSE works together with renowned paint manufacturers. We also gladly accept customer requests.
To achieve EMC shielding in non-metallic enclosures, the inner surface must be provided with a conductive layer to keep electromagnetic radiation away from the outside. This process is called vapour deposition.
For this purpose, ROSE Systemtechnik uses a coating of aluminium to achieve the required conductivity. The coating thickness is approx. 2.5 μm. To ensure an even surface, the enclosure must be cleaned beforehand. Areas that are not to be coated are masked off. For the actual coating process, the parts are placed in a chamber in which a strong negative pressure is generated. In addition, the housing must be earthed. Then an inert gas is introduced into the chamber and charged with an electrical voltage. This creates an electrically charged mist.
An aluminium wire is inserted via preheated ceramic guides and heated with an additional electrical voltage until the aluminium vaporises and mixes with the gas mist. This creates a conductive mist that now settles on the earthed housing. This process continues until the desired layer thickness is reached. The electrical voltage is then removed and the gas is discharged.
On request, we individualise our products with company logos, lettering or special labels as desired by means of mechanical engraving or laser engraving.
Engraving is a process in which a recessed mark or cut is made on a surface to create a pattern or inscription. This involves transferring the design of the pattern or mark onto the material to be engraved. This can be done by hand or with the help of computer software.
The tools used for engraving depend on the material and the type of pattern to be created. An engraver’s graver or a cutter is used to remove the material to create the pattern. Engraving is done by rotating the engraving graver and pressing on the surface of the material to remove the substrate material. The depth and angle of the cut depends on the artwork and can vary to create different effects.
After the engraving process, the material is cleaned and polished to smooth the surface and highlight the engraving. A coloured design for better visibility is also included in the service offered by ROSE Systemtechnik. Machine engraving enables high precision and repeatability in the production of large quantities.
Screen printing is a finishing process with which motifs such as logos are printed on the enclosures. The process is suitable for any surface. In the process, the ink to be applied is pressed with a rubber squeegee through a fine screen that is only permeable at the points that correspond to the desired motif. The screen is compacted with a stencil in all other places.
In pad printing, a soft silicone rubber pad picks up ink that is located in a deeper print image in the surface of a stencil. The pad thus only absorbs ink in the form of the motif to be printed. The pad is then pressed onto the surface to be printed and leaves the motif there. In the case of multi-coloured motifs, the stamping process is repeated with the ink pick-up from other stencils in addition to the other parts of the motif.
Pad printing is particularly suitable for printing on uneven or curved surfaces, as the flexible silicone pad can adapt to the contours of the material. It can be used on many materials such as metal, plastic or glass and makes it possible to produce precise and detailed prints.
Corrosion
Corrosion protection refers to measures to prevent damage to surfaces caused by external influences. Corrosion is a chemical or electrochemical reaction that leads to a change and destruction of materials made of metal, glass, ceramics and polymers. Oxygen, hydrogen, sulphur dioxide, hypochlorous acids, peroxide compounds and the like are among the reactants. A generally known type of corrosion is the rusting of iron.
In the case of metallic materials, metal atoms change into their originally non-metallic chemical compound in this process. This happens when the metal forms a compound together with e.g. oxygen, thus forming metal oxide. Oxidation is a chemical process in which one substance gives up electrons to another substance. An example of the process of oxidation is the reaction of iron with oxygen in the air. When iron is exposed to air, it reacts with oxygen and forms rust (iron oxide). In the process, iron gives up electrons to the oxygen.
Iron oxide has a different chemical structure than pure iron and is less stable, which means that it oxidises further and becomes rust. A thin invisible layer of oxidation first covers the metal. The oxide can prevent corrosion if the layer adheres firmly and without gaps to the surface, thus shielding the metal from the oxygen. This protection is called passivity. Whether it forms on a metal or whether the oxidation leads to corrosion depends on the purity of the metal. The more impure a metal is, the more impervious and thus oxygen-permeable the oxide layer forms, which ultimately leads to corrosion rather than passivation.
There are different types of corrosion protection by coating, including:
There are also hybrid coatings that combine several of these protective mechanisms to achieve higher corrosion resistance. The choice of the appropriate corrosion protection process depends on several factors, such as the type of metal, the environment and the requirements for durability and resistance of the coating.
There are a variety of coatings that can be used for corrosion protection. Some commonly used coatings are:
The choice of the appropriate coating depends on various factors, such as the type of material to be protected, the environmental conditions and the requirements for durability and resistance of the coating.
Various coatings are offered at ROSE Systemtechnik. Special requests are also possible after consultation with the in-house surface technology department (effort, costs, minimum order quantities for desired coating, etc.). To test the corrosion behaviour of the coatings and materials, salt spray is used in accordance with DIN EN ISO 9227. The resulting corrosion provides information about the quality. Consistent quality is necessary to comply with the ISO 9001 standard.
In order to safely shield installed components in industrial enclosures from external influences, suitable seals must be fitted to all openings in the enclosure, e.g. between the lower part of the enclosure and the lid. Various types of seals can be used for this purpose. The standard portfolio includes PU foam, CR round cord, silicone and EMC seals. In addition, other sealings can also be installed at ROSE Systemtechnik by arrangement.
PU foam is a foam made of polyurethane, a plastic material used in a variety of applications. PU foam is made by mixing liquid polyurethane resins with a mixture of gas and catalysts. It has a closed-cell structure, which gives it a high insulating capacity and makes it a popular material for insulation. The seal is also used in the automotive industry, in furniture construction and in the packaging industry.
PU foams are used as standard at ROSE Systemtechnik for aluminium enclosures and are processed in a fully automatic foaming plant. This is process-safe and cost-optimised. Flexible foam has a lower density and is used in upholstery and mattresses.
The advantage of this sealant is that it can be sprayed, which allows it to reach hard-to-reach areas, and provides a seamless seal and insulation. This process is also called “foaming”. After foaming, the foam hardens.
The advantages of PU foam as a seal at a glance:
A CR round cord is a round cord made of a chloroprene rubber. It is a synthetic rubber that has a high resistance to weathering, ozone and ageing. It also has good resistance to oils, greases and chemicals. The CR round cord is often used to seal joints, especially in industry. It is manufactured in various diameters and lengths and sold by the metre.
The processing of CR round cord is simple, as it can be easily cut and shaped to meet specific requirements. After choosing the right thickness and length, the cord is pressed into the groove provided.Due to its high resistance to weathering, ozone and ageing, it is often used in applications that are subject to high stress, such as in the automotive industry, mechanical engineering or the chemical industry.
Silicone gaskets are made of silicone rubber. The material is a synthetic rubber consisting of silicon, carbon, hydrogen and oxygen. It has a high resistance to heat, cold, moisture and UV radiation. Silicone gaskets are manufactured in various shapes, sizes and colours and can be used for a wide range of applications. At ROSE Systemtechnik, they are used as a cord in aluminium and polyester enclosures and are also used as a rectangular profile in stainless steel enclosures. For explosion-proof enclosures, these seals are used as standard.
Characteristics of silicone gaskets:
Due to their high resistance to extreme temperatures and chemicals, as well as their elasticity and weather resistance, silicone gaskets are used in many different industries, including the electronics, food and medical industries.
An EMC gasket to ensure electromagnetic compatibility, consists of two components: a conductive layer of e.g. silver, aluminium, graphite, nickel etc. and an elastic layer with a good sealing effect such as silicone. The amount of conductive components depends on the frequency of the electromagnetic interference, the type and intensity of the interference, the environment in which the seal is used and the requirements of the specific application.
EMC gaskets are often used in the electronics industry to reduce electromagnetic interference between different components and to ensure compliance with EMC standards. ROSE Systemtechnik uses these sealing materials as round cord for aluminium and polyester enclosures. For stainless steel enclosures, however, we use EMC gaskets as a tape due to the design.
Industrial enclosures are usually designed for use in demanding environments where they need to be protected from harmful influences such as dust, water, chemical substances, vibrations or extreme temperatures. In industrial areas, various protection classes for enclosures are therefore relevant: IPxx, NEMA, IKx, EMC protection and chemical resistance. The IP protection classes indicate how well an enclosure is protected against the ingress of foreign bodies (first digit) and water (second digit).
The higher the number, the better the protection. For example, IP68 means that the housing is dustproof and protected against permanent immersion in water. NEMA certifies the same criteria for the US market. The IK code, on the other hand, describes impact resistance according to DIN EN IEC 62262. Electromagnetic interference (EMI) can affect the performance of electronic devices. An enclosure with EMC protection can prevent external electrical signals from entering the enclosure and interfering with the electronics.
Impact resistance according to DIN EN IEC 62262 is divided into 11 different categories and each is assigned an IK code. The IK code 00 certifies no resistance of the enclosure to mechanical impacts. IK11, on the other hand, is the highest IK protection class with a certified impact resistance of 50 joules. The protection levels are determined on the basis of drop tests in which a pendulum weight is dropped onto the enclosure from certain heights. IK stands for “Impact Protection”.
The IK classification is particularly relevant for enclosures used in public areas or in harsh environments, e.g. in street lighting, surveillance cameras or switchgear.
| IK protection level | Impact energy (joules) | Protection against |
|---|---|---|
| 00 | 0 | No protection |
| 01 | 0,15 | Protection against impact of 0.25 kg from a distance of 56 mm |
| 02 | 0,2 | Protection against impact of 0.5 kg from a distance of 80 mm |
| 03 | 0,35 | Protection against impact of 0.5 kg from a distance of 140 mm |
| 04 | 0,5 | Protection against impact of 0.25 kg from a distance of 200 mm |
| 05 | 0,7 | Protection against impact of 0.25 kg from a distance of 400 mm |
| 06 | 1 | Protection against impact of 0.5 kg from a distance of 400 mm |
| 07 | 2 | Protection against impact of 0.5 kg from a distance of 600 mm |
| 08 | 5 | Protection against impact of 1.7 kg from a distance of 300 mm |
| 09 | 10 | Protection against impact of 5 kg from a distance of 200 mm |
| 10 | 20 | Protection against impact of 5 kg from a distance of 400 mm |
| 11 | 50 | Protection against impact of 10 kg from a distance of 500 mm |
The IP protection class (Ingress Protection) indicates how well an enclosure is protected against the ingress of dust or water. The IP protection class is defined in the IEC 60529 standard and consists of the letters “IP” followed by two digits.
The first digit indicates the degree of protection against foreign bodies and ranges from 0 (no protection) to 6 (dustproof). The second digit indicates the degree of protection against moisture and ranges from 0 (no protection) to 9 (protects against temporary submersion). The IP protection class is particularly relevant for electronic devices that are used in harsh environments or outdoors, e.g. in industry, construction, agriculture or outdoor activities.
| Degree of protection against ingress of foreign bodies | Degree of protection in damp and wet environments | ||
|---|---|---|---|
| No protection (diameter > 50 mm) | 0 | 0 | No protection |
| Protected against solid objects larger than 50 mm | 1 | 1 | Protected against dripping water |
| Protected against solid objects larger than 12 mm | 2 | 2 | Protected against dripping water when the housing is tilted up to 15°. |
| Protected against solid objects larger than 2.5 mm | 3 | 3 | Protected against water spray |
| Protected against solid objects larger than 1 mm | 4 | 4 | Protected against splash water |
| Complete protection against contact and dust | 5 | 5 | Protected against water jets |
| Fully protected against contact and dustproof | 6 | 6 | Protected against strong jets of water |
| 7 | Protected against temporary immersion | ||
| 8 | Protected against permanent immersion | ||
| 9K | Protected against water during high pressure/ steam jet cleaning |
The National Electrical Manufactures Association (NEMA) is a standards organisation. It is based in Washington and sets technical safety standards for electronic products that are produced or used on the US market. However, the organisation does not test and certify independently. For industrial enclosures and control cabinets, the protection classes NEMA 1 to NEMA 13 are meaningful. The requirements are similar to those of the IP protection classes, but more complete.
| NEMA protection class | Protection class |
|---|---|
| 1 | Protection against dust penetration and limited protection against dripping water |
| 2 | Protection against dust penetration and limited protection against splashing water |
| 3 | Protection against the ingress of dust and rain |
| 3R | Protection against the ingress of dust and rain, suitable for outdoor use |
| 3S | Protection against ingress of dust, rain and snow, suitable for outdoor use |
| 3X | Protection against ingress of dust, rain, snow and corrosive agents, suitable for outdoor use |
| 4 | Protection against the ingress of dust and splash water |
| 4X | Protection against the ingress of dust and splash water, corrosion resistant |
| 5 | Protection against the ingress of dust and splash water, limited to indoor areas |
| 6 | Protection against the ingress of dust and strong jets of water |
| 6P | Protection against the ingress of dust and strong jets of water, suitable for outdoor use |
| 7 | Explosion protection for gas and steam environments |
| 8 | Explosion protection for gas and steam environments |
| 9 | Explosion protection for dust environments |
| 11 | Protection against dust penetration and limited protection against dripping water |
| 12 | Protection against the ingress of dust, dirt and splash water, suitable for indoor use, for enclosures without pre-embossing |
| 12K | Protection against the ingress of dust, dirt and splash water, suitable for indoor use, for enclosures with pre-embossing |
| 13 | Protection against the ingress of dust, dirt and splash water as well as oil and coolants, suitable for indoor use |
EMC is the abbreviation for “electromagnetic compatibility”. Electromagnetically compatible enclosures protect the installed components from unwanted electrical and electromagnetic effects. External radiation of this kind could otherwise impair the function of sensitive sensor technology. Such interference can come from many different sources, such as electric motors, circuit breakers, radio and television transmitters, mobile phones and other wireless devices. This interference can cause electronic equipment to malfunction or even fail completely.
The EMC of our industrial enclosures is ensured by the fact that the closed metal construct creates a Faraday cage. To create the same effect with plastic enclosures, they are vapour-plated with a conductive layer for this purpose (see vapour-plating).
ROSE Systemtechnik complies with international standards and guidelines. For the high demands on safety and quality, not only the products but also the processes of the company have been certified. The requirements of all certificates held by ROSE are described below.
ISO 14001:2015 is an International Organisation for Standardisation (ISO) standard that specifies the requirements for an environmental management system (EMS). The standard was updated in 2015 and is therefore known as ISO 14001:2015.
The standard provides a framework for companies and organisations to improve their environmental management and minimise environmental impacts. The standard specifies requirements for a systematic approach to identifying environmental impacts, setting targets and plans for improving environmental performance and monitoring progress. The following criteria form the basis for implementing an environmental management system (EMS).
If a company’s environmental management system meets these international criteria, it is recognised under ISO 14001:2015. Certification is carried out by an independent certification body such as TÜV, which checks compliance with the requirements of the standard and issues a certificate if the audit is successful.
ISO 9001:2015 is an international standard for quality management systems. It sets requirements for quality management systems that companies use to meet customer requirements and continuously improve customer satisfaction.
The foundation for a quality management system that enables a company to continuously improve its processes and performance and increase customer satisfaction are:
The AEO F (Authorised Economic Operator – Full) certificate is issued by the customs authorities of the European Union. It is a seal of approval that distinguishes companies that are considered reliable and trustworthy trading partners. To obtain the AEO F certificate, companies must meet a number of criteria set by the customs authorities. These criteria relate to compliance with customs regulations, security standards and financial criteria.
Holders benefit from simplified customs clearance, increased security in international trade, a reduced number of controls and better cooperation with customs authorities. The certificate is of great importance for companies operating in the international supply chain. It is seen by many business partners and governments as an important indicator of a company’s reliability and trustworthiness.
The criteria for the AEO F certificate cover three main areas:
In addition, companies wishing to obtain the AEO F certificate must also demonstrate that they have an adequate accounting process and internal control systems in place to ensure compliance with customs regulations.
DIN EN 16247 is a European standard that defines requirements for energy audits of companies. The aim of the standard is to identify potential energy savings and implement measures to improve energy efficiency. The standard specifies requirements for the energy audit process, including the performance of on-site visits, the analysis of data and the preparation of a report with recommendations for improving energy efficiency.
The specific requirements of DIN EN 16247 include:
Compliance with DIN EN 16247 can help to improve the energy efficiency of companies, reduce costs and promote environmental protection. The standard can be applied voluntarily by companies, but in some countries there are also legal requirements for energy audits based on DIN EN 16247.
DIN EN 45545-2 is a European standard for fire protection requirements for materials in rail vehicles. It is intended to prevent the spread of fire and limit the formation of smoke. It applies to all parts installed in or on a wagon – including interior fittings, panelling, floor coverings, cables, electrical equipment and electronic systems.
The components or materials are divided into component classes depending on the application. In addition, the area of use is relevant. The combination of application area and component class determines the requirement law, which specifies which tests must be carried out to test the materials for their resistance to fire. Unlike many other standards, DIN EN 45545-2 does not refer to installed components or products, but to their materials.
An example of this are the tests on the ROSE Systemtechnik rail enclosures: stainless steel enclosures do not have to be tested because they do not develop smoke gas in the event of a fire. For the aluminium standard enclosures, only the powder coating is tested because it contains polyester, which emits smoke gases in the event of a fire. This means that these tests can then also be carried out on all other aluminium enclosures with the same powder coating. However, a separate test is carried out for each polyester web enclosure because each model has a different material thickness and thus also a different fire behaviour.
DIN EN 15085-2 is a standard for the welding of rail vehicles and parts. It specifies requirements for the quality of welding in rail vehicle construction and serves to ensure safety and reliability there. CL2 represents the highest quality level achievable according to this standard. This level requires the most stringent quality control measures and is typically used for critical components of rail vehicles, such as those that are subject to high loads or that are safety critical.
The EN 15085 online register is a database of companies certified to meet the requirements of the DIN EN 15085 standard. The database contains information about the certified companies, such as their location, contact details and the scope of certification. The database is intended to help customers find suppliers that meet the requirements of the standard and ensure that the products they purchase are safe and reliable.
The requirements of the standard are:
Lloyd’s Register of Shipping (LR) is an independent organisation founded in London in 1760. It offers services in the fields of shipbuilding and operation as well as offshore and energy installations, damage assessment, inspections and certifications, but also training and consultancy.
To be certified by Lloyd’s Register, companies and their products must meet the standards set by the organisation. The requirements concern technology, the laws of a country, environmental compatibility and safety as well as quality but also ethics and integrity. Some standards include ISO 9001:2015 (standard for quality management systems), ISO 14001:2015 (standard for environmental management systems), ISO 45001:2018 (standard for occupational health and safety management) or IEC 60079 (standard for electrical equipment in potentially explosive atmospheres) and SOLAS (Safety of Life at Sea).
The American Bureau of Shipping (ABS) is a leading and independent organisation in the field of classification and certification of ships and offshore facilities. The company was founded in the USA in 1862 and has its headquarters in Houston, Texas.
It sets standards and rules for the design, construction, operation and maintenance of ships and offshore installations to ensure the safety and quality of such facilities. ABS offers a wide range of services, including classification, certification, testing and monitoring. ABS classification marks are affixed to vessels that meet the established standards.
In addition to the classification and certification of ships and offshore installations, the organisation is also involved in the research and development of new technologies and procedures to improve the safety and efficiency of shipping. ABS is also a member of a wide range of international organisations and bodies concerned with the safety and efficiency of shipping.
The DNV certificate is issued by Det Norske Veritas (DNV), an international certification body. The DNV certificate confirms that a company has implemented a quality management system that meets the requirements of the international standard ISO 9001.
UL (Underwriters Laboratories) is an American organisation that tests the risks of materials, components, products and devices with regard to their area of application in order to ensure a uniform level of safety. For example, the mechanical, electrical or chemical properties as well
as the resilience of materials or products etc. are tested under various external influences. The processing and production process is also subject to certain guidelines. UL has developed these especially for the American market. They are recognised on the international market. Individual parameters also form the basis for other standards.
To have a product certified by UL, all installed components must be submitted and tested together with the product, e.g. alternative seals or the materials of the components. There are special requirements for plastics: Only plastics that are listed and have a Yellow Card should be used. Otherwise, all material-specific tests must be carried out. An approved product may thus only be modified to the extent specified in the approval.
As ROSE Systemtechnik products are designed for electrical and electronic components, they are subject to the Low Voltage Directive (also referred to as “Directive 2014/35/EU”). It specifies the European safety requirements for electrical equipment intended for use in low-voltage networks (up to 1000 volts alternating current and 1500 volts direct current).
The directive defines minimum requirements for the safety of electrical equipment to ensure that it does not cause harm to persons or property. These requirements include, among others, the use of suitable materials, the design of equipment, the avoidance of hazards such as electric shocks and the provision of safety warnings and instructions.
The Low Voltage Directive applies to all manufacturers, importers and distributors of electrical equipment placed on the market in the European Union. Compliance with the directive is mandatory in order to obtain the CE mark and to demonstrate conformity with safety requirements.
ROSE Systemtechnik’s non-terminated products, such as industrial enclosures, are manufactured in compliance with standards so that our customers’ end products can be CE marked at a later date.
DIN EN 62208 is a European standard for empty enclosures for low-voltage switchgear and controlgear assemblies. It specifies the general requirements for enclosures and their protective components intended mainly for industrial and commercial applications.
The standard defines the characteristics and properties of the enclosure materials as well as the requirements for mechanical strength, impact resistance and environmental protection. It also provides guidelines for the selection and installation of components within the enclosure, as well as for the testing and certification of the assembled equipment.
The standard covers enclosures for indoor and outdoor applications and applies to all types of low-voltage switchgear. Compliance with the DIN EN 62208 standard helps to ensure that enclosures provide adequate protection for the electrical equipment they contain and reduce the risk of injury or damage caused by electrical faults or environmental influences.
The standard describes the requirements for enclosures which, in combination with components, result in a finished product. Basic properties are described that ensure safe operation.
With reference to the Low Voltage Directive 2014/35/EU, Rose Systemtechnik GmbH is not entitled to provide its products with a CE marking. The main argument here is that these enclosures are subjected to intensive further processing by the customer, i.e. the enclosure itself is processed by attaching inputs and outputs. The same applies to the installation of electrical components or the creation of wiring with electronic components. ROSE Systemtechnik does not provide any information on this. These enclosures are intended to protect the electronic components from dirt and water ingress in as wide a range of applications as possible.
The evaluation of the electrical safety of these enclosures can only be carried out after processing on the part of the customer and, in particular, after equipping with electrical engineering. An electrical safety assessment is not possible when the enclosure is delivered by ROSE Systemtechnik.
However, according to the case law of the ECJ, enclosures can only be CE marked if they are made available on the market for a specific application, e.g. as a component in the context of a kit with specific instructions for the installation of the electrical engineering. In this case, an electrotechnical risk assessment can be carried out because the application is fully known.
Thus, the responsibility of the finished products lies with the customer, as ROSE Systemtechnik acts on behalf of the customer and does not provide the finished products (connectable devices) on the market. The empty enclosures are therefore components that must not be labelled.
The UKCA (UK Conformity Assessed) mark is a new mark of conformity that will be mandatory for certain products in the UK from 1 January 2022. It replaces the CE marking for products placed on the market in the UK. The UKCA mark applies to a wide range of products, including machinery, electronic equipment, medical devices and building and construction products.
However, as the English Low Voltage Switchgear Directive 2016/1101 remains valid, ROSE Systemtechnik is not authorised to provide its empty enclosures with a UKCA marking.
The EAC marking stands for “Eurasian Conformity Marking” and is a mark of conformity that has been used in the countries of the Eurasian Economic Union (EEU) since 2013. The EAEU comprises five countries: Russia, Belarus, Kazakhstan, Armenia and Kyrgyzstan. The EAC marking is placed on products manufactured or sold in these countries. It indicates that the product complies with the technical regulations of the EAWU and is approved for sale in these countries. The EAC marking applies to a wide range of products, including electronic equipment, machinery, medical devices, toys, vehicles and construction products.
The EAC marking must be affixed to the product or packaging and is issued by certified bodies authorised by the governments of the EAWU countries. It is important to note that products manufactured in the EU and bearing the CE marking can usually also be sold in the
EAWU countries, provided they comply with the EAWU technical regulations. However, in some cases an additional conformity assessment may be required.
ATEX is the abbreviation for “Atmosphères Explosibles” and refers to a European directive regulating potentially explosive atmospheres in industrial environments. It comprises two EU directives, ATEX 137 and ATEX 95.
ATEX 137 regulates the minimum requirements for the protection of workers working in potentially explosive atmospheres and requires employers to assess the risks of an explosion and take appropriate measures to protect their employees.
There are three main requirements:
ATEX 95, on the other hand, refers to the certification of equipment and protective systems used in potentially explosive atmospheres and sets out requirements for design, manufacture and conformity assessment.
There are three main requirements:
The guidelines apply to various industries, such as the chemical, oil and gas, food and beverage and other industries where potentially explosive atmospheres may be present.
The ATEX marking is an important part of the ATEX Directive and indicates that a piece of equipment or protective system is suitable for use in potentially explosive atmospheres. Here are some of the most important requirements of the ATEX marking:
IECEx stands for “International Electrotechnical Commission System for Certification to Standards Relating to Equipment for Use in Explosive Atmospheres” and refers to a certification system for electrical apparatus and equipment used in potentially explosive atmospheres. The IECEx system was developed by the International Electrotechnical Commission (IEC) to facilitate the certification and acceptance of electrical apparatus and equipment intended for use in potentially explosive atmospheres. It is based on the IEC 60079 series of international standards, which specify requirements and test methods for the safety of electrical equipment in potentially explosive atmospheres.
The IECEx certification system comprises a series of assessment procedures and certification schemes carried out by independent testing bodies approved by IECEx. Certification includes verification of the electrical equipment’s conformity with the requirements of the IEC 60079 series and a review of the manufacturer’s quality assurance procedures. By certifying electrical devices and equipment according to the IECEx system, manufacturers can ensure that their products comply with international standards and can be used safely in potentially explosive atmospheres.
The EAC Ex certificate is only issued in the countries of the Eurasian Economic Area (EEA). The EEA includes Russia, Kazakhstan, Belarus, Armenia and Kyrgyzstan. The certificate confirms that an Ex product complies with the technical regulations of the EEA and can therefore be freely traded in these countries and used in potentially explosive atmospheres. To obtain an EAC declaration of conformity or an EAC certificate, the product must be tested by an approved conformity assessment body.
The exact requirements and test criteria are specified in the technical regulations and standards for each product type. These may include, for example, requirements for electrical safety, emission and immunity levels for electromagnetic interference or the chemical composition of materials.
The EAC certificate is important for companies that want to manufacture or sell products in the countries of the EEA. Without the certificate, products cannot be distributed or used in
these countries. The EAC certificate is also an important factor for international trade and cooperation between the countries of the EEA and other countries, as it ensures compliance with common technical regulations and standards.
INMETRO stands for the National Institute of Metrology, Quality and Technology (Instituto Nacional de Metrologia, Qualidade e Tecnologia). The Brazilian institute is responsible for the regulation and standardisation of products and services. It was founded in 1973 and develops technical regulations and standards as well as certifications for products.
Industrial enclosures must have a certain degree of protection according to INMETRO requirements, depending on the type of environment in which they are used. This can range from IP54 to IP67 to ensure adequate protection against dust, water and other environmental influences. They must also be made of materials that are safe and able to withstand external influences.
Before being launched on the market, industrial enclosures have to undergo a series of tests to ensure that they meet the stated requirements. These tests include, for example, mechanical stress, chemical resistance or even corrosion resistance. INMETRO works closely with other national and international organisations to ensure that its standards and certifications are internationally recognised and meet the requirements of the global economy.
EXPLOLABS (Pty) Ltd is a service company in South Africa specialising in testing and inspection of explosion-proof electrical and electromechanical equipment. EXPLOLABS’ approved Ex products ensure compliance with South African standards. The testing laboratory is accredited to ISO 17025 by the South African National Accreditation System (SANAS).
Korea KTL stands for Korean Testing Laboratory and is an independent testing and certification body in Korea. It is responsible for testing the safety and performance of electrical and electronic products and ensuring that they meet national and international standards.
KTL also has specific requirements for the materials and design of industrial enclosures to ensure that they are suitable for use in certain environments. These include requirements for resistance to corrosion, temperature resistance, impact resistance, watertightness and electromagnetic compatibility.
To ensure that industrial enclosures meet the requirements of KTL, they have to pass certain tests, including environmental tests such as climate tests, vibration tests and IP (ingress protection) tests. Enclosures that pass these tests then receive the KTL certificate and can be sold on the Korean market.
CCC Ex stands for “China Compulsory Certification for Explosive Atmospheres” and refers to the Chinese certification system for electrical devices and equipment intended for use in potentially explosive atmospheres.
The CCC Ex certification system was developed by the China Certification and Accreditation Administration (CNCA) and is based on the IEC 60079 series of international standards. It specifies requirements and test procedures for the safety of electrical equipment in potentially explosive atmospheres to ensure that such equipment complies with Chinese safety requirements.
The CCC Ex certification scheme comprises a series of assessment procedures and certification schemes carried out by independent testing and certification bodies approved by CNCA. Certification includes verification of the electrical equipment’s compliance with the requirements of the IEC 60079 series, as well as verification of the manufacturer’s quality assurance procedures.
By certifying electrical devices and equipment according to the CCC Ex system, manufacturers can ensure that their products comply with Chinese safety requirements and can be used safely in potentially explosive environments in China.
CCOE stands for “Chief Controller of Explosives” and is an Indian regulatory authority responsible for the approval of explosion protection products. The CCOE is under the Department for Promotion of Industry and Internal Trade (DPIIT) of the Indian Ministry of Commerce and Industry. It tests and certifies products to ensure that they comply with India’s explosion protection regulations. Certified products receive a certificate of approval called a “CCOE Approval”, which is a prerequisite for the sale and use of these products in India.
The CCOE is responsible for implementing the Explosives Act, 1884 and the Explosives Rules, 2008, which regulate the use and sale of explosive substances and products in India. The products regulated by the CCOE include explosion protection products such as electrical equipment for use in potentially explosive atmospheres, fireworks, explosives and pyrotechnic products.
UkrSEPRO stands for “Ukrainian System of Quality and Safety of Products”. It is a Ukrainian system for the certification of products. Certification by UkrSEPRO certifies that the tested products meet the quality and safety requirements of the Ukrainian market. The Ukrainian government commissions various agencies to test and issue certificates according to this system. Products without the UkrSEPRO may not be sold in Ukraine.
The system is based on rules, laws, guidelines and standards that determine requirements for products. These concern the following aspects:
According to UkrSEPRO, industrial enclosures must comply, for example, with the EN 60529 standard “Degrees of protection provided by enclosures (IP code)”.