DIN Rail (35mm Top Hat) | Roll Forming Machine Electrical Cabinet

DIN Rail (35mm Top Hat)

1. Technical Definition

A DIN rail (35mm top hat) is a standardized metal mounting rail used inside electrical control cabinets to securely install electrical and automation components.

The most common DIN rail used in industrial equipment is the 35mm top hat rail, also known as TS35 or EN 60715 DIN rail.

This rail allows electrical devices to be mounted quickly and securely without the need for direct panel drilling.

In roll forming machine electrical cabinets, DIN rails are used to mount components such as:

• PLC modules

• Circuit breakers

• Contactors and relays

• Terminal blocks

• Power supplies

• Communication modules

• Control interface devices

The DIN rail system provides a modular mounting platform that simplifies electrical cabinet assembly, maintenance, and component replacement.

2. Where It Is Located

DIN rails are installed inside the electrical enclosure cabinet, typically mounted on the enclosure backplate.

Common installation locations include:

• Main roll forming machine control cabinet

• Servo drive control cabinet

• Hydraulic control panel

• Stacker automation cabinet

Multiple DIN rails are often installed in parallel rows to organize electrical components efficiently.

The rails are mounted horizontally across the backplate using screws or mounting brackets.

3. Primary Functions

3.1 Provide Standardized Component Mounting

DIN rails allow electrical components to snap into place using standardized mounting clips.

3.2 Improve Electrical Cabinet Organization

The rail system helps maintain a structured layout of electrical components.

3.3 Simplify Installation

Devices can be installed quickly without drilling new mounting holes.

3.4 Enable Easy Maintenance and Replacement

Components can be removed or replaced without major cabinet modifications.

4. How It Works

The DIN rail functions as a mechanical mounting rail for electrical devices.

Typical installation process:

1. The DIN rail is mounted to the cabinet backplate.

2. Electrical components include built-in mounting clips.

3. The component is positioned over the rail.

4. The mounting clip snaps onto the rail profile.

5. The device locks securely in place.

To remove a component, technicians release the clip using a screwdriver or release tab.

This system enables fast and efficient electrical assembly.

5. Types of DIN Rails

35mm Top Hat Rail (TS35)

The most widely used DIN rail in industrial control systems.

Standard width: 35mm

32mm G-Type DIN Rail

A narrower rail used for lighter electrical components.

Less common in modern industrial equipment.

15mm Miniature DIN Rail

Used for compact control devices in small electrical panels.

Slotted DIN Rail

Contains perforations for easier mounting and cable routing.

6. Construction & Materials

DIN rails are manufactured from durable metals to support electrical equipment.

Common materials include:

• Galvanized steel

• Zinc-plated steel

• Stainless steel

• Aluminum

Typical construction features include:

• Standardized 35mm width

• Top hat profile shape

• Reinforced mounting edges

• Slotted or solid mounting holes

Galvanized steel DIN rails are the most common in industrial electrical cabinets.

7. Design Considerations

Engineers consider several factors when installing DIN rails.

Important considerations include:

• Available cabinet space

• Component size and spacing

• Cable routing paths

• Heat dissipation between devices

• Accessibility for maintenance

Proper layout ensures safe electrical operation and efficient servicing.

8. Load & Stress Conditions

DIN rails must support the weight of electrical devices mounted on them.

Typical stresses include:

• Weight of PLC modules and relays

• Vibration from machine operation

• Thermal expansion from electrical heat

• Mechanical forces during installation

Heavy electrical devices may require reinforced rail mounting.

9. High-Speed Production Considerations

High-speed roll forming machines rely heavily on automated electrical systems.

DIN rails support installation of:

• PLC controllers

• Servo drive modules

• Encoder interface devices

• Communication network hardware

Organized DIN rail layouts help reduce electrical interference and improve reliability.

10. Heavy Gauge Applications

Heavy gauge roll forming machines often include high-power electrical control equipment.

DIN rails must support heavier devices such as:

• Large contactors

• Motor protection breakers

• Power distribution modules

Reinforced DIN rail mounting may be required.

11. Light Gauge Applications

Light gauge roll forming machines often use complex automation systems with many smaller devices.

DIN rails support installation of:

• PLC expansion modules

• Relay control systems

• Signal interface modules

• Network communication hardware

Compact layouts are common in these systems.

12. Common Failure Causes

DIN rails rarely fail structurally but may develop issues due to:

• Loose mounting screws

• Corrosion in humid environments

• Overloading with heavy components

• Improper installation on thin panels

Proper installation prevents most problems.

13. Symptoms of DIN Rail Issues

Technicians may notice:

• Electrical devices becoming loose

• Rail movement during machine vibration

• Difficulty snapping devices onto the rail

• Corrosion on the rail surface

These issues may require rail tightening or replacement.

14. Installation Requirements

Proper DIN rail installation includes:

• Secure mounting to the enclosure backplate

• Correct spacing between rails

• Adequate clearance for wiring

• Level installation to support component alignment

Proper installation ensures reliable component mounting.

15. Maintenance Requirements

Routine maintenance should include:

• Inspecting rail mounting screws

• Checking for corrosion or damage

• Ensuring mounted devices remain secure

• Cleaning dust or debris from the rail

These inspections help maintain cabinet reliability.

16. Typical Replacement Cost

DIN rails are inexpensive but essential components.

Typical price ranges include:

Short DIN rail section (300–500 mm)
$5 – $20

Standard DIN rail length (1 meter)
$20 – $60

Heavy-duty or stainless steel DIN rail
$60 – $150+

Installation labor may increase total replacement cost.

17. Safety Considerations

Improper DIN rail installation may lead to:

• Loose electrical components

• Wiring strain or disconnection

• Increased vibration damage

• Electrical system failures

Secure DIN rail mounting is critical for cabinet reliability.

18. Role in Roll Forming Machine Assemblies

DIN rails support electrical control systems responsible for operating many machine subsystems including:

• Roll forming drive motors

• Hydraulic cutting systems

• Punching stations

• PLC automation systems

• Servo feeding equipment

• Machine safety control systems

They provide the standardized mounting platform for electrical components inside the control cabinet.

Engineering Summary

The DIN rail (35mm top hat) is a standardized mounting rail used to install electrical control components inside roll forming machine electrical cabinets.

It:

• Provides modular component mounting

• Simplifies electrical cabinet assembly

• Improves wiring organization

• Allows quick component replacement

• Supports reliable electrical system operation

DIN rails are a fundamental component of modern electrical control cabinets used in roll forming machines.

Technical FAQ

What is a DIN rail?

A DIN rail is a standardized metal mounting rail used to install electrical components inside control cabinets.

What does 35mm top hat DIN rail mean?

It refers to the standard DIN rail profile with a 35mm width and top hat-shaped cross section.

What devices mount on DIN rails?

Common devices include PLC modules, relays, circuit breakers, power supplies, and terminal blocks.

Why are DIN rails used in electrical cabinets?

They simplify installation, maintenance, and replacement of electrical components.

Are DIN rails standardized?

Yes. Most industrial DIN rails follow international standards such as EN 60715.