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Author Archives: A & J Manufacturing

  1. Five Benefits of AS9100 Certification

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    Quality procedures, results and products are critical in any business, but perhaps none more so than aerospace and defense. It’s not hyperbole to say that lives could be at risk if quality management processes aren’t adhered to.

    The two quality standards most often associated with these industries are ISO 9001 and AS9100. While these certifications are not required by law, in order to effectively participate in the aviation space, many suppliers require AS9100 certification. If you want to do business with these suppliers, you MUST be certified. And once you are certified, you’ll need to maintain your certification by meeting the AS9100 requirements on an ongoing basis.

    What is ISO 9001 and AS9100?

    Often considered the fundamental requirement, ISO 9001:2015 is the internationally recognized, foundational quality standard. It’s based on quality management principles like a strong customer focus, top motivations, a process approach and continual improvement, according to iso.org.

    AS9100 uses all of the ISO 9001 standards as a foundation, with additional regulatory requirements pertaining specifically to aerospace quality needs. They’re backed by the International Aerospace Quality Group (IAQG), which includes reps from many major worldwide aerospace companies.

    The base content is identical in both standards, but the AS9100 audit carries additional expectations in the “Product Realization and Measurement, Analysis and Improvement” sections of the requirements. Examples include:

    • Risk management
    • Project management
    • Configuration management
    • Counterfeit part management
    • The human element
    • Additional safety requirements
    • Purchasing
    • Non-conformance

    What are the benefits of being certified?

    There are five main advantages that an ISO or AS9100 certification can bring to manufacturers:

    1. Define your company’s quality control processes – a cornerstone of the certification process, quality control performance metrics, such as on-time delivery, throughput, and overall equipment effectiveness, helps accurately reflect your performance. In turn, these metrics can help you make more educated decisions to improve growth and profitability.
    2. Boost employee performance and productivity – engaged employees are motivated to implement processes that help identify and resolve problems in a timely manner. The consistent auditing process will keep employees focused, while also providing critical feedback.
    3. Provide an improved customer experience – when you employ a quality management process it translates into reduced customer complaints and more overall satisfaction. Optimizing your customer priorities based on their preferences, expectations and needs will reinforce their loyalty to your business.
    4. Reduce waste and improve efficiency – because certification enforces a continuous improvement strategy, you’ll always be seeking ways to reduce waste by implementing preventative measures. When you streamline, every moving part is as effective as possible.
    5. Increase confidence in your manufacturing business – with your certifications, you ensure that you business has all the tools, resources and equipment to produce a quality product or service.

  2. Optimal Airflow in Electronic Enclosures; and 4 Design Tips

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    Thermal management for sophisticated electronics in protective enclosures starts with one fundamental element: airflow. Optimal airflow in electronic enclosures, both within and throughout, can mean the difference between successfully maintaining and cooling your sensitive components and risking costly downtime associated with failures.

    Equipment has specific operating temperature ranges and when put inside of cabinets and enclosures, temperature can become a big issue. Cooling should be considered early in the design process, but having an effective cooling strategy can help in adequately dealing with heat dissipation.

    First: Understanding Heat Transfer

    Heat transfer takes place in three ways: through radiation, conduction and natural or forced convection.

    Heat transfer via radiation occurs through electromagnetic waves, similar to the sun’s energy reaching the earth.

    Heat can also be transferred through conduction between objects. A common example of this is a microprocessor chip cooled using a heat sink, making direct contact with the chip.

    Most systems remove heat through a combination of methods. Going back to the microprocessor chip, it may be cooled using a heat sink (conduction) that includes a fan (forced convection).

    The most commonly used cooling methods for enclosures, in order of increasing cost, are natural convection, forced convection and air conditioning.

    Second: Understanding Airflow

    Natural Convection

    This is the most basic form of airflow. When heat rises, cold air is pushed to the bottom of a space. If convection isn’t properly addressed, a hot spot will form at the top of the enclosure.

    Natural convection cooling is adequate for most applications that generate mild heat. But, an easy solution is passive ventilation, or louvres.

    Louvres are open, unfiltered vents positioned to allow ambient air to be drawn into the enclosure through openings positioned low on the enclosure surface, and to exit through similar openings positioned high on the same surface. They’re also a popular option because they provide some protection against dust entry.

    Forced Convection

    Using the same principles as described above with natural convection, forced convection adds a fan, blower or compressed air to force the warmed air through the enclosure and out through the upper vent.

    Three devices are commonly used: fans, blowers and fan trays

    Axial fans are typically capable of delivering high volumes of air at medium to low pressure

    Blowers, or centrifugal fans, change the direction of the air, typically 90 degrees, and push the air out through a ducted system. They offer higher pressure with a lower flow.

    Fan trays are used to direct airflow to hot spots when there is restricted airflow due to servers, drawers or shelves. It’s basically a chassis with a fan cooling module that can be mounted directly below the sensitive equipment or a hot spot. At A&J we’ve created a separate sub assembly that support fans with related parts such as EMI and dust filters.

    Air Conditioning

    For critical and thermally sensitive applications, or sealed cabinets, air conditioners provide the greatest capacity to transfer heat. Most air-conditioned cabinets are sealed with only inside air circulated inside to prevent moist air from entering and causing condensation.

    Basic Airflow Calculations

    For For ∆T in degrees F: Airflow (ft3/min) = BTU/hr / (1.08 × ∆ΤF) = (3170 × kW) / ∆ΤF

    For ∆T in degrees C: Airflow (ft3/min) = BTU/hr / (1.95 × ∆ΤC) = (1760 × kW) / ∆Τc

    Typical values for ∆Τ are 10C and 18F. Add 25 percent for a safety margin (12.5C and 23F). Note that ∆Τ represents the temperature rise over ambient air temperature. If ambient is too high, it may be difficult or impossible to maintain a safe operating temperature without air conditioning.

    Airflow Calculator

    Design Tips for Component Placement

    • Components with significant heat generation should be given extra space to exhaust the heat and allow for proper airflow around them. Place these items closer to the intake of the AC, if using.
    • Components that run cooler can be stacked closer together. Airlfow is less of a requirement with these pieces because they have minimal effect on overall heat within the enclosure.
    • There should be clearance to walls and doors; keeping the hotter components away from walls of the enclosure allows for better circulation of air within the space.
    • When a component has an active airflow through internal fans, directing the airflow towards the AC intakes will help the cooler to perform more efficiently. It is more beneficial to get the hot air from the equipment into the AC, than it is to get the cold from the AC to the equipment.
    • Special consideration should be made when components have internal fans mounted on its front panel. It is common to recess the front retma bars and/or specify a deeper door to ensure proper airflow facing the front of the rack.

    Thermal Management Solutions to Consider

    When planning your next project design, consider these three solutions:

    1. Fans – one of the oldest solutions to help boost natural ventilation. An air filter should always be used to minimize dust and debris, but ensure that the free-airflow rate (CFM) is three times grater than the calculated flow rate.
    2. Enclosure air conditioners – a viable option when the capacity requires over 1000 BTUH and especially beneficial if you’re operating in an environment that has wide temperature fluctuations.
    3. Air to air heat exchangers – a low-energy and low-maintenance solution that uses a heat pipe to absorb the heat inside the enclosure and transfer it to the outside via a phase-changing liquid under vacuum. However, it requires that the ambient air outside the enclosure be lower than the air inside.

    We’re committed to helping you get the most out of our enclosure cooling options

    Discuss your specific requirements with our engineers to get the most cost effective solution for your cooling needs. Get more information about configuration and placement from our experts.

    Chat with A&J Engineers

  3. Common Misconceptions of Modular Enclosures

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    Are you considering using modular enclosures for a project? Modular enclosures provide plenty of benefits to different industries. However, To ensure you’re making an informed decision before investing in modular enclosures for your project, you must be familiar with these common misconceptions and better understand how misperceptions may hold back their functionality and usefulness.

    Myth 1: Modular Enclosures are Too Expensive

    This is one of the most common misconceptions about modular enclosures. They can indeed cost more than traditional unibody enclosures, but it’s important to factor in the long-term savings associated with their use. Modular enclosures are designed to be customizable and reconfigurable, so they can be used for multiple applications over time without needing to be replaced or retrofitted.

    This means you can spend money on something other than purchasing new equipment every time your needs change, which adds up over the years. Additionally, many modular enclosure manufacturers offer competitive pricing, making them an attractive investment in the long run.

    Myth 2: Modular enclosures are less robust than unibody enclosures

    Enclosures are actually incredibly robust and reliable when it comes to protecting against potential damage. The frame’s strength also allows it to be used in more demanding and hazardous environments than unibody enclosures, such as chemical plants or outdoor locations.

    In addition, modular enclosures come with a range of features designed specifically for safety and security purposes. These features may include a key-operated locking mechanism, tamper-proof hinges, and breakaway gaskets which prevent unauthorized access.

    Myth 3: Setting up a modular enclosure is a labor-intensive process

    This is not necessarily true. While some assembly will be involved, it can usually be done without specialized training. The complexity of the configuration and the number of accessories used will determine how much work is required.

    But even then, it’s typically less than what would be needed for a unibody enclosure that requires fabrication techniques such as cutting, welding, and bending to modify it. So if you’re looking for an easier way to customize your enclosure system, modular enclosures are definitely worth considering!

    Myth 4: Several part numbers must be obtained to complete a modular enclosure assembly

    Most applications require two-part numbers for a complete modular enclosure assembly. While it is true that additional accessories can be ordered to customize the enclosure and make it more suitable for specific application needs – such as feathering in different sidewalls, doors, or covers.

    These are only necessary if extra protection, customization, or flexibility are needed. In most cases, the core frame/assembly plus a pair of sidewalls will provide adequate protection capabilities without requiring additional components. This keeps costs down and simplifies the assembly process for everyone involved.

    To have better understanding, below is a table on how easy it is to request for standard part numbers that offer basic configuration options.

    STANDARD SIZE RACKS/CABINETS

    D E P T H Light Duty Width Medium Duty Width Heavy Duty Width
    21.31″ 22.31″ 24.00″
    26″ 30″ 36″ A1 D1 G1
    A2 D2 G2
    A3 D3 G3
     
    PART NUMBER KEY x x Height – x x Depth/Width – x x x x Configuration

    Reliable enclosures at A&J Manufacturing Company

    After debunking the misconceptions, it’s now clear that you can fully rely on modular enclosures, from reduced construction cost and faster installation to greater adaptability and the ability to house systems of all sizes. Choosing the right enclosure will protect your valuable components from environmental hazards such as dust, moisture, and corrosion.

    A&J offers a wide range of high-quality enclosures for military and industrial applications

    All our products are thoroughly tested to ensure reliability and longevity

    Browse Our Catalog

    With decades of experience designing and manufacturing trusted and reliable enclosures, you can trust that A & J Manufacturing Company has the best solutions for your business needs. Contact us or request a free quote today to get started with finding the perfect modular enclosure for your operations.

  4. Aluminum recycling – how it’s done and why it’s important

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    Aluminum is one of the most abundant metals found on Earth and is also widely recycled across much of the world. Alongside glass and steel, aluminum is one of the easiest materials to recycle. According to the Aluminum Association, nearly 75% of all aluminum that has ever been produced is still in use to this day; with the majority of aluminum cans that you purchase in a store having already been recycled many times over.

    But, aluminum isn’t easy to produce. It’s an extremely energy-intensive process. Extracted and refined from mined bauxite ore, producing virgin aluminum takes an average of 14,000 kWh of electricity to produce just one metric tonne. Increasing aluminum recycling translates to less energy used and a lower carbon impact.

    How is aluminum recycled?

    Recycling aluminum is a lot more straightforward than creating new aluminum and represents the circular economy at its finest.

    Aluminum scrap comes from two primary sources:

    • Fresh scrap, which is the surplus metal left over from the manufacturing and fabrication of aluminum products, mostly found in manufacturing plants
    • Old scrap, which is a discarded aluminum product, like a beverage can

    Aluminum is recycled by being shredded into chips and fed through an infrared sorter to remove any plastic, glass or other contaminants, followed by a magnet which pulls up any scraps of steel. Did you know aluminum isn’t magnetic?

    The chips are then melted down at a temperature of approximately 1,221 Fahrenheit into molten aluminum, and poured into large molds. It takes just two and a half hours for a 10m long ingot to set.

    During the remelting process any paints or lacquers used are vaporized, and an aluminum oxide called dross is produced and reacts with air. To remove the dross, a furnace operator uses a large spatula to skim the dross off the top. The dross is collected, and then goes through its own recycling process to extract residual aluminum.

    Dross is highly toxic and has to be buried in landfills. This dross must be tightly sealed in containers so that it doesn’t leak out and enter groundwater. Engineers at the Worcester Polytechnic Institute are trying to find ways to use the waste product to strengthen cement instead of burying it.

    After an ingot has been removed from its mold, its transported to a rolling mill. The furnace is heated to 995 Fahrenheit, which is hot enough to relax the bonds between the aluminum. It’s then pressed through a series of rollers that roll the ingot thinner and thinner, until the ingot become a sheet of aluminum approximately 0.1″ thick. It’s rolled into a reel approximately 1,000 times its original length!

    Before widespread commercial aluminum recycling, aluminum used to be one of the most expensive metals on the planet; more so than gold.

    Advantages of recycling aluminum and reducing our carbon footprint

    • Thanks to recycling aluminum, more than 90 million tons of carbon dioxide are stopped from being released into the environment each year
    • Recycling aluminum saves more than 90% of the energy costs necessary for primary production
    • It prevents 97% of greenhouse gas emissions than creating new aluminum
    • Recycling aluminum saves 9 tonnes of CO2 emissions and 4 tonnes of bauxite
    • In the US, industrial recycling saves over 90 million barrels of oil annually

    While the production and recycling of aluminum isn’t a perfect process, it’s one of the best solutions we have to make manufacturing across multiple industries greener and more sustainable.

  5. Looking Ahead into 2023 Aerospace and Defense Industry Predictions

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    The aerospace and defense (A&D) industry has shown signs of a strong rebound in 2022, but supply chain and talent issues continue to limit the industry’s growth in 2023. According to Deloitte’s outlook survey, supply chain disruptions and talent shortages may be the biggest ricks or challenges for A&D organizations in 2023. Inflation also remains a challenge for the entire industry–54% of respondents in Deloittes’ survey report that price increases are one of the key risks this year.

    The defense segment remained stable through 2022 and is expected to outperform the commercial aerospace segment as in increase in defense budgets in the wake of Russia’s invasion of Ukraine is boosting demand for military equipment globally. The US defense budget for FY2023 emphasizes perceived strategic threats from China and Russia, with a key focus on electronic warfare and cybersecurity. The president’s request of $872B represents more than an 8% increase.

    According to Deloitte’s outlook survey, 88% of surveyed senior executives indicated that they believe the general business outlook for the A&D industry for the next year is “somewhat to very positive.”

    2023 Aerospace & Defense Industry Trends to watch

    Focus on supply chain visibility and resilience mitigates broader set of risks

    Companies across the defense sector have been forced to learn more details about their supply chains, and where the vulnerabilities and risks are. In order for companies to quickly adjust to sudden disruptive changes, they’ll need a few important tenets:

    • Rapid detection, response, and recovery
    • End-to-end, data-driven, supply change control that allows a company to view raw materials, semi-finished goods and finished products starting from the “suppliers suppliers” to the “customers’ customers”. And it will be important to prepare for these disruptions before they happen via scenario planning and war gaming.
    • Emergency stockpiles, safety stocks, and diversified sourcing from offshored, nearshored and/or reshored suppliers
    • Collaboration of private and public supply chain stakeholders

    Companies will likely emphasize supply chain diversification, including local sourcing and nearshoring, to avoid concentration risk. They’re also likely to build relationships with suppliers from countries with free trade agreements (FTAs).

    Moreover, companies will need to reinforce the need for cybersecurity, cloud privacy, and the resilience of the systems and automation to be prepared effectively for ask risks with core operations and with key suppliers.

    Acceleration of digital thread and smart factory can drive improved efficiencies

    Smart factories are built on Industry 4.0 technologies that combine cyber digital and physical systems. And they can bring even greater value when they are connected through the digital thread – a single, seamless strand of data stretching from the initial design of a product through to its operation. It connects engineering, supply chain, manufacturing and aftermarket touchpoints.

    A good starting point is to connect the PLM, ERP/MES and asset management toolsets. The continuous flow of data between these systems forms a body of knowledge that will help maximize quality, efficiency and compliance.

    It can drive unprecedented value:

    1. Designing with 360-view of product lifecycle
    2. Differentiating products with increased flexibility and improved quality
    3. Driving manufacturing efficiency by connecting disparate systems
    4. Identifying new ways to deliver service
    5. Enriching the sales and marketing experience

    A new federal initiative, AM Forward, is a voluntary compact among large manufacturers to help their smaller suppliers increase their use of additive manufacturing or 3D printing. Investments like this could help drive supply chain resilience and reduce lead times.

    Attracting, retaining, and developing top talent remains a challenge

    While the majority of jobs losses related to COVID-19 have been added back, the workforce turnover rate remains high, and an aging workforce is contributing to the current shortage. Meanwhile, automation and advanced digital technologies are driving the need for a workforce with more advanced aerospace engineering, math, data science and digital skills.

    According to the Deloitte outlook survey, three out of five senior industry executives surveyed believe that offering clearer pathways for career progression is the best strategy to attract, retain, and develop top talent.

    Lowering emissions and implementing sustainable manufacturing remain business priorities

    According to the International Data Corporation, 80% of global manufacturers will incorporate environmental sustainability in their products by 2024, which can improve sales by 3%. Sustainability has already become an integral part of business decision marking as both consumers and corporate purchasers increasingly consider carbon footprints when making buying and investment decisions.

    A&D primes set a target to reduce greenhouse gas (GHG) emissions, water, waste, and energy and are progressing toward meeting their 2025 and 2030 sustainability targets. For instance, major A&D primes have set a target to reduce more than 50% of GHG emissions by 2030.

    GHG emissions scope

    In addition to the well-established steps (such as switching to alternative energy sources or improving energy efficiency), a much larger variety of emissions-reducing innovations is now available, including low- or zero-carbon raw materials, greener product designs, and improved overall product usage that strengthens the circular economy.

    Innovation accelerates growth in emerging areas

    Emerging markets such as space, supersonics/hypersonics, and AAM are poised to change the industry landscape and capabilities in the coming years. 2023 will likely be an important year for these emerging markets in terms of investments, technology evolution, and regulation. According to Deloitte’s outlook survey, organizations are most likely to invest in space-related technologies and AAM in 2023.

    2023 could see further developments in earth observation/remote sensing, satellite communications, and technology development. As industries are combating climate change, space companies can monitor and track Earth and benefit manufacturers with advanced technologies such as IoT to improve productivity and reduce emissions.

  6. Equipment Enclosures & Accessories for the Energy Sector

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    Electronic enclosures in utilities have a wide range of applications and are essential for the safe operation of utility operations. However, they can be subject to various challenges, such as extreme temperatures, dust, dirt and water immersion, vibration, and shock. To ensure optimal performance and safety, the enclosure must be properly designed and protected against these elements.

    Our electronic enclosures and accessories provide robust protection from external sources such as dust and dirt and can perform under harsh environments with temperature and humidity changes.

    Electronic enclosures that serve the energy industry

    Renewable energy includes solar, wind, and geothermal sources, which are growing in importance daily. With many years of experience, our engineers have built equipment racks designed for the different needs of these alternative energy sources.

    Solar

    The most abundant energy source on Earth is solar power. This form of renewable energy has become the fastest-growing sector in the world, with more and more countries investing heavily in solar technology. 

    Solar panels have allowed it to power both airplanes and charge electric vehicles. Still, the space industry was one of the earliest adopters of this type of renewable energy. The Vanguard 1 satellite, launched in 1958 and remains the oldest human-made object still orbiting Earth, used solar power to operate.

    On a much larger scale, solar energy is being produced all over the world. California’s Mojave Desert is home to Ivanpah Solar Power Facility, one of the world’s largest operating solar thermal energy plants. 

    Energy from the sun is expected to produce 50% of the world’s total energy. With that in mind, we can build and design racks applicable to solar power.

    Enclosure requirements

    ●   Durable to withstand weather hazards, UV radiation, high temperatures

    ●   Lightweight, corrosion-resistant, durable

    ●   Easily modified to meet specific applications

    Wind

    Wind power has been around for centuries, with the first example of wind power technology being used in Ancient China in 2000 BC. Fast forward to the 1940s, and the first modern turbine was built in Vermont. Today, however, one of the world’s largest turbines can be found across the US – particularly going to Hawaii, where 20-story tall turbines with blades the length of a football field are located.

    What’s more, wind power is unique in that it does not require any water to operate – no wonder that by 2030, it is expected to save around 30 trillion bottles of water in the US alone. As such, this renewable energy source is becoming increasingly popular and will remain an integral part of our energy portfolio for many years. 

    Wind energy is one of the most economical renewable sources today. It’s an essential part of the world’s energy mix, providing 6.5% of all electricity generated in 2020.

    Enclosure requirements

    ●   Lightweight, weather-resistant

    ●   Ruggedized construction to withstand harsh environments

    Geothermal

    Geothermal energy is an incredibly versatile and environmentally friendly form of energy generation. It has one of the lowest carbon footprints of all energy sources because it typically only involves drilling two to three wells, meaning there is no need for transportation or further processing. 

    Furthermore, its use can extend far beyond typical power plant applications. Geothermal energy can be used to heat buildings, grow plants in greenhouses, heat water for fish farming, pasteurize milk, and even pipe it underneath roads and sidewalks to keep them clear of snow. Its reach is limited only by the imagination. 

    With its low carbon footprint and wide range of applications, geothermal energy is a great way to reduce our reliance on fossil fuels while still providing a reliable and sustainable form of energy. 

    Geothermal energy is already heating many homes in the US with continued strong support from Bill Gates as he also added a geothermal startup to his clean energy fund. This renewable power is designed to use the earth’s natural temperature to heat and cool homes and doesn’t burn fossil fuels.

    Enclosure requirements

    ●   Durable materials such as aluminum

    ●   Withstand high temperatures due to the hot steam

    ●   Offer protection against dust, dirt, and other harsh environments.

    Electronic enclosures manufactured for water treatment facilities

    Water treatment is any process that improves the quality of water to make it more acceptable for a specific end-use. It could be for drinking, industrial water supply, irrigation, river flow maintenance or recreation. 

    The control & management of water treatment facilities is a complex task requiring thousands of measurement devices to provide consistent data to various locations. That’s why these devices must be in proper cabinets, which is why our custom-designed racks & electronic enclosures have been specifically designed for the water treatment industry.

    Enclosure requirements

    ●   Must perform under harsh conditions, often requiring use of a gasket for weatherproofing

    ●   Shock & vibration resilience

    ●   Corrosion-resistant material

    ●   Impenetrable by rodents

    Custom equipment racks & accessories by A&J Manufacturing

    We are committed to ensuring our customers receive the right products for their intended applications. In the utilitiesindustry, specific enclosure requirements are needed to ensure electronic devices are safe from outside elements. We can achieve any specifications you have in mind with our custom services.Our engineers invest significant time in understanding the application’s end-use with extensive pre-planning so that the result is an enclosure with tight tolerances and all components functioning as required. We want to collaborate with you to ensure you’ll have a scalable renewable energy or water treatment facility enclosure. Contact us now for more information regarding our electronic enclosures or . request a quote today!

  7. How to calculate temperature rise in your enclosure

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    When designing an electronic enclosure, temperature rise must be carefully considered to ensure all devices will function properly and for safety reasons. Heat is generated from all electronic components, and uncontrolled temperature accumulation can lead to malfunction. We’d argue it’s the most important factor to take into account when designing your rack or enclosure. The service life of components are halved and the failure rate is doubled in the event of a 10 K temperature increase.

    Several ways to control temperature rise include ventilation, heat sinks, and air conditioners. By understanding how temperature rise occurs and choosing the suitable temperature control method, designers can create safe and reliable electronic enclosures.

    What causes temperature rise?

    Adding heat to an object or material causes the temperature to rise. The amount of heat added is determined by the surrounding environment’s temperature and the pace at which heat is generated.

    Many electronic components generate heat when power flows through them.

    • processors and power supplies
    • semiconductor devices
    • variable frequency drives (VFDs)
    • programmable logic controllers (PLCs)

    This heat must be dissipated to prevent the component’s temperature from rising to a level that would cause it to malfunction or fail.

    It’s important to consider all these factors when calculating the rise of the enclosure’s temperature too:

    • Environmental conditions outside , such as direct sunlight, can increase the internal heat load.
    • Since hot air rises, many vertically mounted enclosures will be hotter at the top versus the bottom. Additionally, the overall orientation of the enclosure affects how heat dissipates. Horizontally mounted enclosures experience significantly more complex heat transfer mechanisms.
    • The enclosure’s construction materials and finishes will affect heat dissipation. For example, unfinished aluminum or stainless steel doesn’t radiate heat as effectively.

    How to calculate the temperature rise in an enclosure

    Below is a set of steps to calculate your enclosure’s temperature rise:

    • The first thing you should take action on is identifying the electrical input power indicated in watts/square foot. You can do this by taking the amount of heat dissolved within the enclosure expressed in watts and dividing it by the square feet of the enclosure’s surface area.
    • Once you have the electrical input power, you can use the graph underneath to find the approximate temperature rise. To do this, locate the electrical input power at the bottom of the graph. Follow the line vertically from the point until it intersects one of the temperature curves. Use the top curve if your case is untreated aluminum or stainless steel. If your enclosure is painted metal or non-metallic, use the lower curve.
    • Finally, draw a horizontal line from the intersection to the graph’s vertical axis. This will give you an estimated number of degrees that the internal temperature of the case will rise above the surrounding air temperature.
    sealed enclosure temperature rise

    Heat Dissipation in Electrical Enclosures

    (Ti-Tu) = Qv / (k*A), where

    • Qv – watts to dissipate
    • Tu – ambient temperature
    • Ti – permitted internal temperature
    • k – heat transfer coefficient
    • A – enclosure surface area

    By following these steps, you can better understand how much heat your electrical enclosure can safely dissipate without exceeding its temperature rating.

    Tips for reducing temperature rise in your enclosure

    There are several ways to reduce the amount of heat dissipated within the enclosure, such as:

    • Reducing the size of the enclosure
    • Using a material with high thermal conductivity
    • Adding ventilation
    • Adding a heat sink (ex: fins or liquid coolant)
    • Adding forced air via an internal air conditioner or fans

    Safely dissipate the heat generated by your electronic components

    Don’t hesitate to contact us for help with your enclosure design and calculating your enclosure temperature. We have the expertise and experienced engineers to help you select the suitable size, and ventilation for your enclosure to ensure that it can safely dissipate the heat generated by your electronic components.

  8. EMI / RFI shielding: what it does and why it’s important

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    EMI, or electromagnetic interference, and RFI, or radio-frequency interference, are both types of electromagnetic radiation. EMI is emitted by electronic devices and can interfere with the proper functioning of other electronic devices, while RFI is emitted by radio waves and can interfere with radio signals.

    EMI and RFI shielding is a process of enclosing electronic devices in a material that absorbs or reflects electromagnetic radiation to protect the devices from interference.

    It can prevent everything from minor crackling during broadcasting to deadly malfunctions in aircraft safety equipment. If left unmitigated, it can disrupt the essential functions of electronic devices or erase or damage data. Even satellites in space need to be shielded from EMI/FRI to function properly.

    Common sources of EMI/RFI include cell phones, microwaves, power lines and computer circuits. There are all natural causes of these signals such as auroras, solar flares or lightning.

    EMI / RFI shielding

    What is EMI / RFI shielding, and what does it do?

    EMI/RFI shielding is a process or material used to protect electronic equipment from EMI and RFI. EMI/RFI shielding can protect against various sources, including radio waves, microwaves, and electrical currents.

    EMI/RFI shielding creates a barrier between the electronic equipment and the source of interference. This barrier can be made with a variety of materials.

    Materials used for EMI/RFI shielding

    For EMI/RFI shielding, a variety of materials can be employed. The following are the most frequent materials:

    • Metals
    • Conductive plastics
    • Carbon-loaded plastics
    • Conductive coatings
    • Metal mesh

    Metals are the most common material used for EMI/RFI shielding. They are effective because they reflect and absorb electromagnetic radiation.

    Importance of EMI / RFI shielding in electronic devices

    EMI/RFI shielding is essential in electronic devices because it can help to reduce or eliminate interference that can lead to errors, data loss, and equipment damage. Shielding can also help improve electronic device performance by reducing interference from outside sources.

    EMI/RFI shielding creates a barrier between the electronic equipment and the source of interference. This barrier is produced with various materials, including metals, conductive plastics, and special coatings.

    How to choose the right EMI / RFI shielding for your needs

    When choosing EMI/RFI shielding for your electronic devices, it is vital to consider the type of interference you are trying to protect against, the level of protection you need, and the environment in which the electronic devices will be used.

    Some EMI/RFI shielding types, such as metal shielding, can block a wide range of frequencies. However, metal shielding can also block signals you may want to receive, such as radio waves. In addition, metal shielding can interfere with the proper functioning of some electronic devices.

    Other EMI/RFI shielding types, such as conductive plastics and special coatings, can be customized to block specific frequencies while allowing others to pass through. These materials can also be used in various environments, including wet or humid ones.

    Common applications for EMI / RFI shielding

    EMI/RFI shielding is used in a variety of industries, including:

    • Automotive
    • Aerospace
    • Telecommunications
    • Medical
    • Mass transit systems
    • Navigation and vehicular control systems

    Keep your electronics interference-free

    If you’re looking for ways to protect your electronic devices from interference, look no further than EMI and RFI shielding. Enclosed devices in a material designed to absorb or reflect electromagnetic radiation to keep them functioning correctly. At A&J we use a .140 diameter tubular gasket (210-1130) that is added to the extrusion grooves and consists of a silicone inner core that is plated with silver / aluminum for the seams between the frame members that are joined together.

    Our enclosures are attenuated to 60 DB from 150 Hz to 1 million Hz and 40 DB from 1-2 million Hz in accordance with MIL-STD-461G for EMI/RFI shielding. Our team of professionals can help you determine the type of shielding your rack or enclosure needs and install it quickly and efficiently. Contact us today!

  9. Rack Mounting Options for your Electronic Equipment

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    A rack mount is a description of a hardware device capable of being mounted in an equipment rack. All types of electronics and computing devices come in rack-mounted packages including servers, test instruments, telecommunications components, which are bolted to the side frames of the rack. Note: shelves are available for equipment that is not rack mounted.

    Measuring cabinet dimensions, specifically depth

    Before ultimately choosing a rack mounting option, let’s first review how to properly measure your rack space. As a reminder, cabinets or enclosures are traditionally referred to by their external dimensions. But in most cases, the rack depth is 4 to 6 inches less than the external cabinet depth.

    To measure the rack depth, measure the distance between the forward-most part of the front rail to the rear-most point of the rear rail. A&J typically recommends 34 in. (86.36 cm) or greater cabinets for use with equipment that have an average depth of 28 in. (71.12 cm). The 6 inches (15.24 cm) at the back between the equipment and the back door or panel allows for cable management, airflow and maintenance access.

    Equipment mounting options

    Originally mounting holes were tapped with a particular screw thread, but has since become problematic where equipment is frequently changed because the threads are easily damaged or the mounting screws can break off. Both problems render the mounting hole unusable.

    Tapped-holes were then replaced by clearance-hole racks. Holes are large enough to permit a bolt without binding and fastened in place using cage nuts.

    The third innovation has been square-hole racks. These racks allow boltless mounting where the weight of the equipment and small retention clips are all that is necessary to hold equipment in place.

    The structural support

    A key structural weakness of front-mounted support is the bending stress placed on the both the rack itself and the mounting brackets of the equipment. Our A&J racks can incorporate front and rear rails that may be moved forwards and backwards that allows equipment to be supported by four posts, but also easily installed and/or removed.

    Our standard AJR 150 Series 4-post racks are 22.31″ (566.6 mm) wide with three depths: 26″, 30″, 36″ (660.4 mm to 914.4 mm). The extra width and depth enables cabling to be routed with ease and deeper equipment to be installed. It can also accommodate “Zero-U” accessories such as PDUs and vertical cable managers in the space between the rear rails and the side of the enclosure.

    Rails (slides)

    Often used for heavy equipment that requires regular servicing, a pair of rails can be mounted directly onto the rack which allows the component to slide into the rack along the rails. The equipment can then be bolted to the rack (as described above) or the rails may also be able to fully support the equipment in a position where it has been slid clear of the rack. Consider purchasing a cable management arm, which folds the cables attached to the server or component and allows them to expand neatly when the rail is slid out, without being disconnected.

    Tools required

    You will need some of the following tools to rackmount your equipment:

    • Philips No. 1, No. 2, and No. 3 screwdrivers
    • Flat-blade No. 1 and No. 2 screwdrivers
    • Allen and adjustable wrenches
    • Needlenose pliers
    • Level
    • Electrostatic discharge (ESD) wrist strap
    • ESD mat

    Rack Mounting Tips & Guidelines

    • Install the heaviest equipment and storage devices in the lowest position in the rack to prevent the rack from becoming too-heavy and prone to tipping over.
    •  Install any remaining equipment from the lowest system upward into the rack.
    • For applications that require high-density cabling, you may need 1U of horizontal cable management for every 1U of patch panels or switches.
    • Ensure the rack is properly secured to the floor or ceiling and level before installing any components.

  10. How We Build Quality into Each Enclosure We Make

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    Of course one of A&J Manufacturing’s primary goals of manufacturing is building a quality product. But, quality also means planning to avoid possible problems and defects. It’s a continual process that is more than just the final inspection before your enclosure or rack is shipped.

    We want to obtain full customer satisfaction through the consistent delivery of high quality electronic enclosures and racks. Internally, we leverage various methods, such as Lead Manufacturing and Six Sigma, but each method has a few things in common:

    1. Continuous improvement
    2. Consistency
    3. Teamwork as part of our culture
    4. Routinely measure and analyze
    5. Training

    By our definition, quality is not a quick fix, but rather a long-term outlook.

    We use the best materials and construction techniques available

    Our electronic equipment enclosures are built to last, and we stand behind every one of them. Our commitment to quality is evident in every aspect of our operation, from the modern inspection systems we use to the multiple visual inspections that every component undergoes during production.

    At A & J Manufacturing, we only use the highest quality components in the production of our items, such as:

    • ASTM B209. This is the Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate.
    • ASTM B221. This is the industry standard specification for aluminum and aluminum alloy extruded bars, rods, wire, profiles, and tubes.

    The degree of protection required for industrial equipment and complex electronics is very demanding. Machined aluminum has the highest quality of durability, toughness and rigidity when compared to other types of enclosures. And they are perfect for precision applications wherein dimensional tolerances are critical.

    Maintaining quality while work is in progress

    Our quality management system extends beyond our product and materials to include our facilities, training and certifications, process monitoring and inspection points.

    1. Facilities. Quality can’t be maintained on our production floor without clean and organized areas that are prepared for work. And all manufacturing equipment and CNC machines must be in good order to deliver the level of precision required for proper assembly.
    2. Training & Certification. We have earned accreditation for two of the world’s most widely recognized quality management standards, including:
      • AS9100D. According to NQA, this establishes quality management system requirements to improve quality, cost, and delivery performance for businesses worldwide. Our AS9100 First Article Inspection is a rigorous process that ensures every component meets our high standards.
      • ISO 9001:2015. Advisera states that this benchmark sets the standards for a company that wants to offer goods and services that meet consumer demands and laws while making clients happy.
    3. Process Monitoring. We have documented process controls in place with procedures for assembly that allow us to maintain consistency and quality in our manufacturing.
    4. Inspection Points. We utilize multiple inspection points to examine previously assembled or machined parts throughout the manufacturing process. Inspections are performed both manually and with our Hexagon Arm CMM machine to detect any incorrectly placed components and to confirm accuracy.

    Our commitment to “Made in the USA” and “Buy American”

    The first “Buy American” Act was passed by Congress and signed into law by President Hoover in 1933. Products must meet two requirements: 1) the end-product must be manufactured in the US and 2) more than 95% of the cost of all component parts must also be manufactured in the US (revised under the Trump administration).

    A&J is committed to being a “Made in the USA” manufacturer:

    • Manufacturing all kits, accessories and enclosures at our CNC machine shop in Foothill Ranch, CA
    • Purchasing our aluminum raw materials from US manufacturers
    • Purchasing ancillary components from US manufacturers

    By partnering with US suppliers, we can easily visit with them in-person to ensure their products meet our customer needs. And when we manufacture things ourselves, we can adapt quickly to design changes and customer inputs. Beyond this commitment, we can help lessen the burden on government purchasing agents by ensuring easily demonstrable compliance with the Federal Acquisition Regulation (FAR) and giving them the option to buy from a US, women-owned, small business.

    Customer satisfaction is our top priority

    At A & J Manufacturing, we are committed to providing the highest level of customer satisfaction possible by focusing on timely delivery and exceptional quality, and we work hard to comply with all customer requirements from start to finish.

    We also protect confidential customer information and prioritize the health and safety of our employees, customers, suppliers, and community. We have established ourselves as a leader in the quality equipment racks industry by consistently meeting or exceeding our customers’ expectations.

    If you’re looking for a reliable, high-quality product, look no further than A & J Manufacturing. We build quality into all equipment racks we make, and we’re always looking for ways to improve our products and services. Send us a message or request a quote today to learn more about what we can do for you.

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