MicroFlex e190
ABB
High-Performance Enclosure for a Leading Industrial Robot Servo Drive.
ABB | Designing A Servo Drive Controller Enclosure | Industrial Design | User-Centred Design, Testing, Design For Manufacture
An innovative case design that enables modular connectivity, enhances thermal performance, and streamlines manufacturing for reduced costs and increased commercial adaptability.
The Journey
ABB Motion, a global leader in the motor drive industry, is known for its award winning MicroFlex range of servo drive controllers. To maintain their edge in a competitive market, they sought our help to develop a new enclosure that would not only integrate new features but also align with evolving industry standards.
Working closely with the ABB team, we engineered a compact modular enclosure system allowing for installation in close spaces. The enclosure also incorporates a hybrid passive/active cooling system to optimize thermal performance, as well as streamlined components and manufacturing processes to reduce overall costs.
The Result? An adaptable, high-performance drive controller that has continued to be a product leader for ABB for over eight years.
The Design Challenge
Our task was to integrate a range of new features all while minimising the number of components and simplifying assembly—creating a design built for lasting value.
The enclosure needed to be compact enough to mount easily in tight spaces, addressing practical installation challenges faced by users. At the same time, it had to improve thermodynamic performance to effectively manage the heat generated by ABB’s powerful motor control technology, ensuring reliable operation.
Our Design Solutions
Through extensive concept design and prototyping, we developed an innovative case design with minimal fixings that clips together and mounts via a concealed base plate, reducing manufacturing, assembly, and installation costs.
The semi-external heat sink enables side-by-side installation with other drives or heat-generating devices while efficiently dissipating heat. This design allows the smart cooling fan to shut down at low power, conserving energy and enabling silent operation.
The Delivery
The MicroFlex e190 is a compact, highly efficient controller featuring a modular, side-by-side mounting system, exceptional thermal performance, and minimal construction. These qualities have made it a reliable, market-leading product facilitating robot automation for over eight years.
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