Electrical Control Panel Solutions
Get a Quote NowElectrical Control Panel Fabrication Overview
Brock Solutions operates one of the largest CSA Certified and UL Listed panel fabrication operations in North America. Whether your needs are project-based or looking for electrical control panel fabrication outsourcing services, we are focused on optimizing your total cost of ownership. Brock Solutions is focused on quality, continuous improvement and developing long term partnerships with organizations across a variety of industries. We work with companies looking to improve quality, optimize their supply chain and drive costs out of their business. Our approach is to gain an understanding of our clients business and develop strategies to achieve their goals. Our engineering depth and ample capacity allow us to deliver large complex systems from either of our facilities in the US or Canada and our volume purchasing power ensures the most competitive material pricing and on time delivery.
Companies that manufacture their own panels often struggle with consistency, quality, competitiveness and the unsettling fluctuations in work volume and resources when it is not their core focus. Panel fabrication is our core focus, and quite simply, is what we do day in and day out.
Electrical and Industrial Control Panel Types
Brock Solutions designs, assembles, wires, and functionally tests complete industrial controls ranging from control stations and multi-panel systems, to complete self-contained packaged control rooms. Our portfolio covers a broad range of panel types, and includes:
A Variable Frequency Drive (VFD) is a motor controller that varies the frequency and voltage supplied to an electric motor. A VFD panel can extend equipment life by providing protection from issues such as overloads, phase protection, under and overvoltage conditions, etc. Brock maintains partnerships with leading VFD product manufacturers such as ABB, Siemens, Allen-Bradley, Schneider, among others. Brock builds VFD panels to meet various NEMA ratings such as NEMA-1, NEMA-12, NEMA-3R, NEMA 4, NEMA 4X and support various types of drives such as AC VFDs, DC Drives, Liquid-Cooled Drives and Soft Starts.
Variable Frequency Drive (VFD) Control Panels
PCRs/E-Houses/I-Houses are ideal for turnkey projects, or projects with very short installation windows between Factory Acceptance Testing and start-up. Brock Solutions has successfully implemented many projects in which the electrical and automation hardware was supplied in an “Engineered-to-Order” pre-wired and pre-tested Packaged Control Room (PCR). Brock has delivered PCRs to multiple industry sectors.
Packaged Control Rooms/E-Houses/I-Houses
Programmable Logic Controller (PLC) panels are used in applications to reduce size, provide control and monitoring of remote I/O with ease of logic modification over conventional relay-based panels. Brock maintains partnerships with leading electrical control panel product manufacturers such as Allen-Bradley/Rockwell, Siemens, GE, Schneider, ABB, among others. Brock’s PLC panels can be found in most industry sectors worldwide.
PLC Panels
Network/Communication Control Panels are designed to link multiple networks throughout industrial and/or manufacturing facilities. Brock’s Network/Communication Panels serve as the backbone for industrial IT and manufacturing control operations, and can be found in data centers of Fortune 500 manufacturers and international airports.
Network / Communication Control Panels
Power Distribution Panels (PDP) divide an electrical power feed into subsidiary circuits while providing overcurrent protection. Brock’s PDP Panels can be found in most industry sectors worldwide.
Power Distribution Panels
MCCs consist of one or more cabinet sections with power bus for mounting of individual devices such as circuit breakers, fuses, drives, soft starters, and contactors to provide short-circuit protection, isolation and control of various loads. Brock Solutions configures MCCs and MCPs to meet specific engineering requirements for unique applications within a variety of industries.
Motor Control Centers (MCCs) and Motor Control Panels (MCPs)
Junction Boxes and Marshalling Cabinets provide a common area for terminating multiple devices at a convenient location for maintenance and troubleshooting purposes within industrial environments. Brocks junction boxes and Marshalling Cabinets enable clients to reduce time during new system installations and/or system retrofits. Many options exist including custom sized panels and quick connect configurations
Junction Boxes
For industrial process and manufacturing environments where there are requirements for local control application, Brock manufactures a variety of control stations such as E-Stop Boxes, Start-Stop Boxes, Fault-Reset Boxes, Yellow Control Stations, and hand-held control stations. Control Stations are made from a variety of industrial-grade plastics and metals, and are effective for controlling a single device or a few devices in a defined area within a plant.
Control Stations
Human Machine Interface (HMI) Operator Panels provide a user-friendly graphical interface for operators and maintenance to monitor, control, and troubleshoot equipment and/or production-line operations. HMI Operator Panels come in different hardware configurations (e.g., free standing, arm mount, wall mount) and industrial design classifications to meet NEMA requirements in different industrial environments. Brock maintains partnerships with leading HMI product manufacturers such as Siemens, Allen-Bradley, Schneider, GE, among others. Brock’s HMI panels can be found in most industry sectors worldwide.
HMI Operator Panel
Supervisory Control and Data Acquisition (SCADA) panels provide supervisory control and data acquisition for oversight of multiple process areas within a large manufacturing or industrial facility. Brock maintains partnerships with leading SCADA product manufacturers such as Wonderware, IFIX, WinCC, FactoryTalk, ThingWorx and Ignition, among others. Brock’s SCADA panels can be found in most industry sectors worldwide.
SCADA Panels
Operator Control Desks are designed to support requirements for dedicated manual control and immediate response time to equipment and production line operations. Typical applications include large-scale, complex industrial environments such as nuclear power and steel-making blast furnaces where there are high operational risks and the need for enhanced safety precaution. Brock Solutions builds Operator Control Desks to clients’ design specifications.
Operator Control Desks
Brock Solutions supports the Solar Power industry with a variety of types of solar panels, including PV (Solar) Inverter Panels, PV (Solar) Re-Combiner Panels, PV (Solar) Combiner Panels, and Low-Voltage (LV) Electrical Switch Gear.
Photovoltaic (PV) Solar Panels
Panel Services offered include:
Project / Program Management
Design
- Electrical design
- CAD
Panel Fabrication
- Custom assemblies
- High volume manufacturing
- Custom bus bar solutions
- Liquid cooled drives
Material Procurement
- Centralized materials management
- Volume purchasing power
Testing / QA
- Fully documented Panel Test and Quality Procedure
- Full Load Testing
- Factory Acceptance Testing (FAT)
- Panel Certification to CSA and UL
- All tests and quality checks are fully document and traceable to the assembly level
Logistics
- Cross border shipments
- Incoming goods
- Shipment of final product to customers globally
On-site Services
- Panel Fabrication
- Machine Wiring
- Installation
- Commissioning and Startup
Outsourcing / Contract Manufacturing
Control Panel Fabrication Operations
Brock Solutions operates one of the largest CSA-Certified & UL-Listed panel fabrication operations in North America. Highlights include:
Panel manufacturing facilities in both Kitchener, Ontario, Canada, and Irving, Texas, US
- 50,000+ square feet of capacity
- Designed for both highly customized and high volume repetitive manufacturing requirements
- Full-scale manufacturing of “Engineered-to-Order” pre-wired and pre-tested Packaged Control Rooms (PCRs)
- Wide range of power sources and test loads to support full load and factory acceptance testing
- Machine shop for custom fabricated assemblies and busbar systems
- Material handling equipment capable of manipulating small devices, to complete packaged control rooms, all tracked by our in-house reporting and ERP system
- Flexible manufacturing—allows for panel fabrication from either location, or both locations simultaneously
- WBE (Women’s Business Enterprise) Certified
What makes us different is that in peak times we can balance the manufacturing loads between the two facilities so that we can ensure a fast turnaround time for panel orders regardless of the size.
Brock Solutions’ Electrical Control Panel Fabrication Project Methodology
Brock Solution’ well-defined panel build project methodology can be applied to any project or program regardless of size. Our methodology covers all steps in the project life cycle from initial information gathering to final system acceptance, delivery, and continuous improvement activities. Time is spent upfront with our customers to ensure specific requirements of the project are captured. Checks and balances are in place to ensure these requirements are being met throughout the project life cycle and that continuous feedback on progress is provided.
Below are examples of the typical steps followed and resources involved in panel build projects and outsourcing programs:
Program Management
- Dedicated Program Manager assigned on all outsourcing programs to regularly interact with the client to ensure program requirements are being met
- Resource planning to account for fluctuations in work volumes
- Identifying areas for standardization in materials and design to reduce cost and promote consistency across the outsourcing program
- Business development efforts including working with the clients estimating and design teams to support development of estimates and proposals for their end customers
- Conduct quarterly business reviews held with all stakeholders
Project Management
- Provide single point of contact for scheduling, progress updates and coordination
- Work with Materials Management to procure project materials and sub-assemblies
- Provide interface to Fabrication and Quality teams
- Manage subcontractors and 3rd party suppliers
- Forecast capacity requirements and schedule work in appropriate locations to meet customer needs
Information Gathering
- Determine requirements of the project/program including scope, delivery, quality and financial goals
Value Engineering
- Determine alternate design and materials to support product enhancements and cost reduction
Project/Program Costing
Pre-Fabrication
- Develop fabrication processes specific to application (i.e. break system into subassemblies for high volume builds)
- Panel Certification to CSA and UL
- Setup facility according to project requirements (i.e. process flow, assembly line, access to special equipment and tooling etc.)
Fabrication
- Fabricate first article
- Fabricate sub-assemblies
- Integrate 3rd party content
- Final assembly and wiring of system while documenting all fabrication steps
Quality
- Apply standard testing procedure or develop custom testing and quality checks specific to program
- In process checks/testing
- First article validation and acceptance
- Final testing to agreed upon quality standard
- Full load testing and Factory Acceptance Testing (FAT) as required
- Final product certification (CSA, UL, CE)
- Complete documentation and traceability of product and quality process
Shipping and Logistics
- Coordination of incoming goods from global suppliers
- Leverage existing logistics network to establish best fit for application
- Final shipment to customer location including customs and brokerage activities
Continuous Improvement
- Project post-mortems and lessons learned involving all stakeholders
All activities are a collaborative effort with regular interaction and input from our customers. Our panel build project methodology is proven and ensures that projects are delivered on time and within budget, irrespective of their size, scope, and complexity.
Outsourcing & Contract Manufacturing
Companies that manufacture their own panels often struggle with consistency, quality, competitiveness and the unsettling fluctuations in work volume and resources when it is not their core focus.
Panel outsourcing and contract manufacturing are a core competency of Brock. Brock is experienced serving as a contract manufacturer supporting the long-term needs of large global companies across many industries. All outsourcing and contract manufacturing programs have a dedicated Program Manager assigned to regularly interact with the client including quarterly business reviews held with all stakeholders to ensure program requirements are being met. A key focus of the Program Manager is to look beyond the day to day activities and plan for the future. Typical activities include planning for fluctuations in work volumes and identifying opportunities to standardize design, material, quality and approach across our customer’s organization while maintaining flexibility to accommodate unique situations.
Our goal is to develop long term partnerships that are mutually beneficial and meets the business needs of our customers growing organizations while providing a significant return on investment as quickly as possible.
