Powering Safety in the Skies: Switchgear for Aircraft Seat Test Lighting
Company: CWB Electrical Engineers Ltd | Location: Bedfordshire | Sector: Aviation
Bedfordshire based CWB Electrical Engineers Ltd specialise in automation and control systems and have for many years, utilised these skills in niche industries such as research and development facilities. Working closely with companies across the UK and beyond, they also provide guidance and advice while turning their clients’ ideas into reality.
Proteus have been building custom distribution boards and control boxes for CWB Electrical Engineers for over 12 years now. Our journey together began when CWB was introduced to our custom design department via their local CEF branch, which at the time was Luton.
CWB Electrical had designed and was due to begin installation of their first generation Crash Test Lighting System and was looking for a manufacturer who could accommodate manufacturing a one-off batch of custom distribution boards which not only complied with the relevant regulations but also had automation control built into them.
CWB Electrical sent us their prototype designs, requirements and system constraints. We opted to recommend a standard 3 phase distribution board but modify it to accommodate the specifics of the test system setup. This had the advantage of keeping the system as simple as possible, but also keeping the lead time as low as possible, which was a key factor in the project at the time.
The design was approved by CWB Electrical and 4 off bespoke control boxes were manufactured, delivered on time and installed and commissioned by CWB Electrical. This was the first generation of Proteus switchgear to feature on a CWB Electrical Crash Test Lighting System. It has been functioning for over 12 years and has never failed. Together with the lighting system, it has completed over 4000 tests.
In April 2019, CWB Electrical approached us again, as they had been commissioned to install their generation 2 Crash Test Lighting System at a facility in Buckinghamshire. The requirements of this system were slightly different from the last as this system was being incorporated into the existing site infrastructure. Again, resulting in the modification of existing products available. This system has been running trouble free for almost 4 years and has completed more than 5000 tests.
In their latest Crash Test Lighting project, CWB Electrical have been working to provide their latest generation 3 Crash Test Lighting System for a bespoke new crash test facility. The facility gives their client the largest sled testing capability in the UK and ensures they’re testing their products to global standards.
With a close working relationship with both Tom Danton at CEF Leighton Buzzard and the Proteus Industrial factory, CWB Electrical was able to share their requirements once again with our technical team to achieve the exact switchgear solution they needed.
The lighting system is the most advanced and energy efficient installed to date. As such the switchgear is more advanced than previous versions. The switchgear also includes various modifications and additions requested by CWB Electrical to make the installation of the switchgear much easier and faster than standard units. Features include a red “power on” indicator lamp in the base of each distribution control box which acts as an easy indication from the ground that the system is in an active condition. Other modifications internally such as additional Neutral and Earth bars each side of the board and adding panel trunking into the distribution board more than halves the installation time as each cable can be stripped and terminated at each circuit breaker.
There is also an additional compartment which houses the system control for each distribution board. It includes contactor and timer arrangements, surge protection and main isolators for each part of the system.
Understanding the unique and tailored solutions Chris Burton and CWB Electrical offer their customers, it’s been very fitting to extend our services to his team and provide a completely bespoke switchgear offering to aid the technical installations they’re involved in. This offering was also complimented by the steel cable management being supplied by our sister company, also Telford based Tamlex.
CWB Electrical asked if Tamlex could supply 75x75mm steel box trunking with pre punched 20mm holes at certain dimensions. Once the drawings were supplied, we manufactured 12 off special 3m lengths all pre punched as requested. This saved CWB Electrical a significant amount of installation time.
