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In early 2023, a leading automotive manufacturing plant in Germany embarked on a comprehensive automation upgrade to increase production efficiency and reduce downtime. The project involved installing over 200 new sensors, actuators, and control devices across three production lines.
Figure 1: Automotive manufacturing plant where TSM Distribution Boxes were deployed
The existing electrical distribution system was outdated and couldn't accommodate the new smart devices. Engineers needed a robust, flexible solution that could handle increased connectivity requirements while withstanding the harsh industrial environment.
The engineering team faced several significant challenges in implementing the new automation system:
Space constraints: Limited panel space required compact yet high-capacity distribution solutions
Environmental factors: Dust, moisture, and temperature fluctuations demanded IP67-rated enclosures
Signal integrity: Sensitive sensor signals needed protection from electromagnetic interference
Maintenance requirements: Quick access for troubleshooting without disrupting production
Future expansion: The system needed to accommodate potential future upgrades
Figure 2: Complex wiring in industrial control panels requiring organized distribution
After evaluating multiple options, the engineering team selected the TSM-Series Distribution Box for its superior features and flexibility. Specifically, they deployed 18 TSM-18 units throughout the production facility.
Figure 3: TSM Distribution Box installed in the automotive manufacturing facility
The TSM Distribution Boxes provided:
IP67 protection against dust and moisture
High-density terminal arrangement saving 40% space compared to alternatives
EMI shielding for sensitive sensor signals
Clear marking and identification systems
Tool-less access for maintenance and modifications
Reduced installation time by 35% compared to traditional methods
Eliminated signal interference issues that plagued previous systems
Provided flexibility for last-minute design changes without rewiring
Enabled future expansion with 30% spare capacity
The installation team followed a systematic approach to implement the TSM Distribution Boxes:
Planning: Detailed mapping of all connection points and signal types
Mounting: Secure installation of distribution boxes at strategic locations
Wiring: Organized cable routing with proper strain relief
Termination: Precision connection of all field devices
Testing: Comprehensive verification of all signals and connections
Documentation: Complete labeling and system documentation
Figure 4: Technician installing and wiring the TSM Distribution Box
The modular design of the TSM boxes allowed the installation to proceed in phases, minimizing disruption to ongoing production operations.
The implementation of TSM Distribution Boxes delivered significant measurable benefits:
30% reduction in installation time compared to previous methods
Zero signal integrity issues reported since implementation
40% less space required for electrical distribution
67% faster troubleshooting and maintenance access
100% uptime during the transition period
Figure 5: Completed automated production line with TSM Distribution Boxes
"The TSM Distribution Boxes were instrumental in the success of our automation upgrade," said Karl Schmidt, Lead Project Engineer. "Their compact design, reliability, and ease of installation helped us complete the project ahead of schedule while exceeding performance expectations."
The manufacturing plant has since standardized on TSM Distribution Boxes for all future expansion projects and has recommended them to other facilities in their global network.
