Subrack: Our Proven Mechanical Core for Modern Distributed Control Systems (DCS)
Engineered for Flexible, Reliable, and Scalable Industrial Automation
As we partner with clients globally in their transition towards smart manufacturing, traditional rigid automation pyramids are rapidly evolving into decentralized, modular Distributed Control Systems (DCS). At the heart of this evolution is our Subrack solution—the preferred mechanical platform for DCS field nodes, enabled by its high-density layout, hot-swappable modules, and fully redundant design.
To us, a Subrack is far more than an enclosure. It is the critical physical foundation we provide to empower modular, scalable, and downtime-free industrial control architectures.
Through deep collaboration with industrial users worldwide, we focus on solving these critical pain points:
Expansions or Process Changes Require Shutdowns: Modifications to rigid conventional cabinets often lead to prolonged production downtime.
Single-Point Failures Halt Entire Lines: Most field nodes lack adequate redundancy in power, cooling, and communication.
Complex Wiring and Protracted Commissioning: Point-to-point wiring increases labor costs and makes Factory Acceptance Testing (FAT) time-consuming.
High-Bandwidth Demands of Industrial Ethernet: While fiber optics become essential, many systems lack integrated high-density fiber management.
Low Mechanical Reuse Across Machine Models: Custom enclosures for different machine types drive up R&D, inventory, and lifecycle costs.
Our Subrack technology is specifically engineered to address these challenges—delivering modular expansion, continuous uptime, and rapid deployment for our clients.
Form Factor: 19” rack, 3U/4U height, 84HP width
Module Capacity: Supports up to ~12 I/O, communication, or safety modules per frame
Redundancy Design: Dual power inputs, dual fan groups, hot-swappable maintenance
Connectivity: Front quick-connect interfaces, rear terminal blocks, optional IP67 rating
Fiber Management: Supports up to 96 × MTP® ports (1,152 fibers) within a 4U chassis
Protocol Compatibility: Industrial Ethernet, PROFINET, EtherCAT, fiber ring networks
Reusability Benefit: Enables >90% cross-model module reuse
We design our Subracks to enable complete micro-DCS nodes within a single frame. Based on the 19” standard and 84HP horizontal rails, one of our units can house up to 12 functional modules, forming a fully capable decentralized controller.
Value for Our Clients: Adapt processes by swapping or adding modules—no rewiring needed. Achieve zero-downtime expansion for flexible manufacturing.
Our power and cooling modules are built for industrial-grade redundancy: dual-feed power, dual fan groups, and hot-swappability. Even during a module failure, the system maintains 100% load, ensuring production continuity for critical industries like petrochemicals, energy, and pharmaceuticals.
With front-access quick-connect interfaces (IP67 optional), our Subrack solution reduces dependency on traditional control cabinets.
Documented Results: Wiring workload decreased by over 40%, FAT can be performed on the production floor, and overall project cycle time reduced by approximately 15%.
To meet the migration of fieldbuses to fiber, we provide a high-density fiber-optic DCS solution. A single 4U chassis can support up to 1,152 fibers, making gigabit and 10-gigabit communication between distributed nodes simple and highly scalable.
Our standardized mechanical design allows I/O, communication, and safety modules to be reused across different machine variants.
Client Savings: Reduced R&D and inventory costs, minimized spare part requirements, and up to 30% savings on field maintenance expenses.
Our Subrack technology is more than a hardware component—it is the mechanical anchor for decentralized DCS architecture, a catalyst for flexible and scalable machinery, and a key enabler of high-availability, zero-downtime automation.
Choose our Subrack solution to simplify control logic, accelerate deployment, and ensure your production runs without interruption.
Contact us today to discuss integrating this mechanical core into your next DCS project.
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