Tim Drysch, head of electrical at GfA, is trained in handling the unusual, the complex, and the unexpected. The key, according to Tim, is understanding the environment, the challenge and finding simple, integrated solutions.
Here are three challenges that show how bespoke electrical design can turn a problem into a solution.
Challenge 1: The Baggage Conveyor Fire Door
The Situation: At a major international airport, fire shutters are required over baggage conveyor belts to prevent the spread of fire within airside terminals.
The Considerations: This presents a unique conflict of interest. The primary function of the door is to close to stop a fire. However, if the door closes while a suitcase is passing underneath, it will rest on the object, failing to create a smoke-tight seal and compromising the fire rating. Furthermore, the system needs to be reliable; if the mains power fails, the door must remain able to close in power loss.
The Solution: GfA utilise a PLC to create a "handshake" between the door and the conveyor system.
● Intelligent Obstacle Detection: The system uses photo beams. If a fire alarm triggers whilst the door is open and a bag is blocking the beam, the control panel allows the conveyor system to move the belt in forward or reverse until the obstruction is cleared. Only when the beam is clear does the conveyor system send a signal to our panel to close. Once the door has left the open position the conveyor is inhibited.
● Battery Intelligence: The design includes several monitoring systems, for example the battery backup. It constantly checks the voltage and acts depending on the battery status feedback.
The Situation: At a major international airport, fire shutters are required over baggage conveyor belts to prevent the spread of fire within airside terminals.
The Considerations: This presents a unique conflict of interest. The primary function of the door is to close to stop a fire. However, if the door closes while a suitcase is passing underneath, it will rest on the object, failing to create a smoke-tight seal and compromising the fire rating. Furthermore, the system needs to be reliable; if the mains power fails, the door must remain able to close in power loss.
The Solution: GfA utilise a PLC to create a "handshake" between the door and the conveyor system.
● Intelligent Obstacle Detection: The system uses photo beams. If a fire alarm triggers whilst the door is open and a bag is blocking the beam, the control panel allows the conveyor system to move the belt in forward or reverse until the obstruction is cleared. Only when the beam is clear does the conveyor system send a signal to our panel to close. Once the door has left the open position the conveyor is inhibited.
● Battery Intelligence: The design includes several monitoring systems, for example the battery backup. It constantly checks the voltage and acts depending on the battery status feedback.
Challenge 2: High-Security Logic
The Situation: For high-security applications, such as museums housing cultural treasures or cash-handling centres, standard locking is insufficient. These sites often require heavy-duty physical locking mechanisms or bollards that engage when the door is closed.
The Considerations: The challenge isn't just locking the door but also preventing the door from destroying itself. If a user tries to open the door while heavy mechanical locks are engaged, the motor could cause catastrophic damage to the door curtain. Conversely, the system must ensure the door is actually locked before giving a "secure" signal.
The Solution: The design service implements a strict logic sequence using a PLC and limit switches.
● Verification: The system incorporates strict interlocking protocols to ensure reliable communication between the door, locking mechanisms and other security functions. The system cannot be operated until all the conditions of the interlock are met to safeguard access to the building.
● Fault Detection: If the door hits the floor but the locks fail to engage (perhaps due to misalignment), the system recognises this "fault condition" and locks out the operation, preventing misuse until the security breach is resolved. It also monitors lock switches when the door is open, via volt-free signals to indicate to control rooms the lock status alongside any errors.
Challenge 3: The Universal Retrofit for Retail Logistics
The Situation: A major retailer and distribution customer needed to upgrade loading bays across a vast network of sites.
The Considerations: The customer required a "universal" solution that could handle varying equipment levels at different depots. They needed a single control panel that could integrate dock levellers, traffic lights, inflatable shelters, and door controls. Crucially, they wanted to minimise the time installers spent on-site wiring complex connections.
The Solution: GfA designed a modular, combined control panel.
● Integration: The panel combines two interlocks ensuring that neither the dock or the door could impact each other, achieved through door position monitoring and proximity sensing.
● Fitter-Friendly Design: To address the installation challenge, the panels were pre-wired and pre-tested prior to dispatch. In the field, clear connection diagrams make for easy connection to the DIN rail meaning installers don't need to decipher complex schematics on-site; they simply connect specific wires to specific terminals, significantly reducing site time and wiring errors.
The Situation: A major retailer and distribution customer needed to upgrade loading bays across a vast network of sites.
The Considerations: The customer required a "universal" solution that could handle varying equipment levels at different depots. They needed a single control panel that could integrate dock levellers, traffic lights, inflatable shelters, and door controls. Crucially, they wanted to minimise the time installers spent on-site wiring complex connections.
The Solution: GfA designed a modular, combined control panel.
● Integration: The panel combines two interlocks ensuring that neither the dock or the door could impact each other, achieved through door position monitoring and proximity sensing.
● Fitter-Friendly Design: To address the installation challenge, the panels were pre-wired and pre-tested prior to dispatch. In the field, clear connection diagrams make for easy connection to the DIN rail meaning installers don't need to decipher complex schematics on-site; they simply connect specific wires to specific terminals, significantly reducing site time and wiring errors.
Whatever your challenge, GfA’s electrical design team and technical team provides the logic that sits between the door and the site's specific needs. Call GfA today on 01926 452452 and start work on your project requirements.
www.gfa-elektromaten.com
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