Modular Rackmount System

APC Technology has shipped one of the largest pieces of equipment to have been assembled on site.

The 19” modular rackmount equipment consisted of five individual bays bolted together, weighing more than 1.3T and over 3m long and 2m high. Each bay features:-

• A dimmable overhead light assembly capable of producing the required range of lighting on the operator console.
• A thermostatically controlled four fan extraction system for heat dissipation located in the roof.
• Coiled cable mount isolators to protect the installed equipment from potentially harmful external vibrations.
• Innovative mounting arrangement for ease of installation.

The equipment installed within each bay varied dependent on the client’s requirement. Installation included 19” LCD displays, power distribution units, keyboard display units and fibre optic break out trays (FOBOT) plus designated slots with brackets for additional items to be added on the project’s site.

Creative Approach Used to Map Complex Wiring Requirements

The project required over two hundred interconnecting cables made to IPC610 & IPC620 standards, then housed within the racks. The complexity of the wiring included ensuring the correct length was calculated prior to installation, minimising the bend radius and reducing the chance of snagging when in operation. During internal discussion on how to manage this complex issue the engineering department opted to build a full scale prototype of the racks to enable a real time wire map to be created. The construction though simple utilised our in-house 3D printing and laser cutting capabilities to create accurate representations of individual elements of the design. This facilitated the identification of unforeseen challenges prior to the build, ensuring production time lines were maintained once installation began.

In-House Capabilities Combined with Team Work Solves Wire Radius Challenge

To ensure optimal performance, wiring needs to be kept to a minimum bend radius otherwise it can lead to EM radiation and metal fatigue which can drastically affect a wires resistance. Additionally fibre optic cables were used in the build and excessive bending can cause microbending and macrobending losses. Engineering Manager explained how APC Technology came up with a solution. APC Technology’s Engineering team explained that having both engineering and manufacturing teams based at their South Australian head office is highly beneficial for clients, as it allows quick engagement across departments to resolve any challenges. When the team identified the wire radius issue, they leveraged their in-house 3D printing capabilities to rapidly design and manufacture multiple bespoke connector backshell variants. This proactive approach enabled them to address potential problems across various locations within the racks and provide a solution to the client while keeping them informed of the situation.

The racks are part of a project win through Raytheon Australia announced last year. The 2nd phase is currently underway at APC Technology.