Client
Our client is a leading provider of critical industrial equipment, offering manufacturing, supply, installation, system integration, and after-sales service solutions for a wide range of industries and applications.
Scope
The scope included the complete mechanical and electrical design of a six-bay switch panel enclosure for a dual 2400 HP, 600 VDC motor drive system. The work covered 3D CAD modeling, bus bar engineering, custom brackets, thermal management, structural FEA, airflow analysis, fabrication drawings, and documentation.
Why APA?
Clients trust APA for our technical depth, transparent communication, and proven track record in power‑distribution and industrial automation projects.
Challenge Involved
● Managing high current density and maintaining safe temperature rise under 2800 ADC continuous operation.
● Achieving uniform thermal distribution within a heat-dense enclosure.
● Designing brackets and bus supports to withstand short-circuit forces and handling loads.
● Optimizing component layout within a compact footprint while ensuring accessibility and serviceability.
● Engineering efficient airflow paths using a combination of blower-based and AC-unit cooling.
● Ensuring manufacturability through standard sheet metal fabrication processes.
Design process
APA Engineering followed a structured, analysis-driven design approach:
● Requirements gathering (SLDs, datasheets, applicable standards, and environmental conditions)
● 3D CAD design of the enclosure, internal framework, and component layout
● Bus bar and support bracket design with appropriate spacing and insulation
● Ventilation and thermal engineering through airflow optimization
● Structural FEA of brackets, bus supports, and the internal frame
● Thermal and airflow analysis to validate cooling performance
● Preparation of fabrication drawings, part drawings, sub-assembly drawings, main assembly drawings, and BOM
● Final documentation, including design drawings, analysis reports, and revision records.
Value delivered
APA Engineering delivered a fully engineered, production-ready six-bay DC drive panel enclosure optimized for performance, reliability, and manufacturability. Through integrated mechanical, electrical, thermal, and structural engineering, the team minimized design risks and enabled seamless fabrication and long-term industrial operation.
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