Custom DIN Rail Assemblies

A customized DIN rail assembly offers a standardized, modular, and space-efficient solution for mounting and organizing electrical components, like circuit breakers, terminal blocks, and other industrial devices. DIN rail assemblies support simplified installation, maintenance, and scalability of electrical systems, and they are widely used in industrial control systems, automation, and electrical distribution for their simplicity and efficiency. 

At Peerless Electronics, we offer custom-assembled DIN rails as part of our Value-Added services, which are free to Peerless customers. Today’s post explores this valuable service in detail, offering more information about how it works, various customization options, common use cases, and how it can help organizations save time and money.

DIN rails are metal rails, usually steel, that safely assemble and encase components in equipment racks and control cabinets, conserving space and providing efficient electrical connections. DIN rail mounts come in various sizes, with the most common being the top hat DIN rail measuring 35 mm wide. The name derives from the German Institute for Standardization, translated from "Deutsches Institut für Normung," where the rail-mounting system was first established in the late 1920s.

Custom-assembled DIN rails offer a seamless solution for organizing electrical devices safely and securely within an application, providing easy installation and removal of electrical devices without additional hardware. However, DIN rail mounts often need customization to suit specific application needs. Customizing DIN rail assemblies involves tailoring specific aspects, such as the rail type, material, length, device positioning, and enclosure protection, to adapt to specific industrial and electrical setups. Tailoring these aspects of the system, which are detailed below, helps improve overall reliability, safety, and ease of maintenance.

Although the top hat rail is the most common, some electrical and industrial applications may require alternate DIN rail types, such as miniature rails or G-type rails. For example, miniature rails are smaller in width (15mm) and suitable for compact installations. G-type rails, on the other hand, are wider and deeper than the top hat and better suited for heavier components and older installations. Customizing DIN rail systems with specific rail designs to support the components’ size and weight helps improve the system's reliability.

DIN rail mount enclosures are the protective housing or enclosures used to protect DIN rail systems’ mounted electrical components. DIN rail assembly enclosures are critical in working environments where dust, moisture, debris, or other factors can threaten the sensitive electrical devices mounted on the rail system. For example, heat-sensitive components may require additional thermal management within the enclosure, and custom ventilation slots, fans, or heat sinks can be integrated into the enclosure design to prevent overheating.

DIN rail styles encompass the variations in size, shape, material, and design of DIN rails, and customization provides tailored solutions to fit the exact requirements of an application. This is especially important for unique setups in industrial, commercial, or specialized environments. For example, an application may require a short DIN rail assembly or a special DIN rail clip design to ensure installation ease and component organization efficiency. Customizations can include specific DIN rail material types, sizes, and lengths, as well as other features like perforations, snap-on mechanisms, or pre-drilled holes.

Custom-assembled DIN rails are critical to enhanced performance in a wide variety of industrial settings, offering flexibility and protection for electrical component organization within applications. Following are some specific examples of how custom DIN rail assemblies can improve the reliability, safety, and scalability of industrial electrical and control systems.

DIN Rail assemblies for electrical switchgear are critical for managing and organizing electrical components in power distribution systems. They provide a structured and efficient method for organizing devices like circuit breakers, relays, transformers, and communication equipment inside the switchgear cabinets. For example, switchgear in heavy industrial settings often operates in high-temperature environments. Therefore, a custom DIN rail assembly design may incorporate thermal dissipation properties for better durability and long-term functioning.

Customized DIN rail assemblies are often essential in industrial environments using systems for process control and monitoring, such as a water treatment plant. In this environment, high levels of moisture and chemicals are prevalent, so a custom DIN rail assembly may include stainless steel or coated aluminum DIN rail mounts to prevent rusting. These custom DIN rail assemblies may also require NEMA-rated enclosure boxes to protect sensitive electronic components from water exposure and damage.

Custom DIN rail assemblies are integral for managing control components within factory automation systems, including sensors, relays, and motor controllers. To ensure these sensitive components remain secure in factory environments, DIN rail customizations can include heavy-duty DIN rail mounts to combat high vibrations and integrated ventilation to prevent components from overheating.

Overall, custom DIN rail assemblies are instrumental in keeping electrical components secure, protected, organized, and accessible within demanding industrial environments. Optimizing the DIN rail mounting and assembly features to fit the unique demands of the environment ensures better reliability, safety, and scalability of electrical control and other systems.

We’ve already touched on the many benefits of customized DIN rail assemblies, including ensuring better long-term performance and adaptability of electrical systems. However, let’s recap the benefits of customizing the design, layout, and materials of DIN rails to address electrical and control system challenges.

• Reduces unproductive labor (no cutting or tooling required)
• Reduces installation time
• Streamlines maintenance and troubleshooting 
• Provides a tailored fit for better space optimization
• Integrates safety features for improved protection
• Provides scalability for system upgrades and expansions
• Ensure regulatory compliance by meeting industry standards
• Incorporates better durability for harsh environments
• Reduces long-term costs with precise design, supporting safety, durability, and longevity

Peerless Electronics is an authorized stocking distributor for the world’s leading manufacturers and suppliers within the military, aerospace, industrial, transportation, and medical sectors. However, supplying quality electrical parts is only part of what we do to support clients worldwide. To ensure a truly customized experience, Peerless also supports every purchase with top-notch value-added services, such as customized DIN rail clip assembly, lending customers the ability to transform orders into top-quality, customized experiences. 

The Peerless Value-Added (VA) Experience, which also includes custom-tailored technical support, offers quick turnaround to save time, maintain workflow, lower costs, and support efficient workforce allocation. At Peerless, customization, quality, and service are paramount to doing business the right way - by putting customers first.

What components can be included in a custom DIN rail assembly?

The specific components will depend on your application’s requirements, whether for industrial automation, power distribution, or specialized monitoring systems. Peerless Electronics carries thousands of components that can be integrated into a custom DIN rail assembly - some of our key manufacturers to name a few would include Entrelec, Carlo Gavazzi, CBI and Altech.

What types of DIN rails are available for custom assemblies?

We can customize any DIN rails purchased on the Peerless Electronics website as part of our Value Added support services. 

Can DIN rails be cut to custom lengths?

Yes, DIN rail mounts can be cut to your specified length, ensuring a custom-tailored fit.