{"id":7272,"date":"2026-02-19T09:00:00","date_gmt":"2026-02-19T08:00:00","guid":{"rendered":"https:\/\/tps-electronic.com\/?post_type=case_studies&#038;p=7272"},"modified":"2026-02-19T14:15:16","modified_gmt":"2026-02-19T13:15:16","slug":"retrofit-circuit-breaker-design-panel-modernization","status":"publish","type":"case_studies","link":"https:\/\/tps-elektronik.com\/en\/case-studies\/retrofit-circuit-breaker-design-panel-modernization\/","title":{"rendered":"TPS Elektronik Delivers Advanced Circuit Breaker System Design and Embedded Control Modernization"},"content":{"rendered":"\n<h2 class=\"wp-block-heading\">Initial Situation<\/h2>\n\n\n\n<p>A company in the heavy industrial automation sector approached <a href=\"https:\/\/tps-elektronik.com\/en\/\" type=\"page\" id=\"1008\">TPS Elektronik<\/a> to modernize an aging electrical protection platform used in power distribution cabinets.<\/p>\n\n\n\n<p>The existing circuit breaker panel design had been in operation for more than 20 years and no longer met current technical and operational requirements.<\/p>\n\n\n\n<p>Key challenges included:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The protection concept no longer aligned with current safety and monitoring expectations.<\/li>\n\n\n\n<li>Mechanical components showed wear, limiting functional expansion.<\/li>\n\n\n\n<li>The embedded control logic lacked scalability and structured fault handling.<\/li>\n\n\n\n<li>No digital documentation or design files were available; only one physical sample unit existed.<\/li>\n\n\n\n<li>The original supplier was no longer able to support production or upgrades.<\/li>\n<\/ul>\n\n\n\n<p>TPS Elektronik was commissioned to execute a complete retrofit, covering electronics development, mechanical redesign, and embedded software modernization.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Technical Challenges<\/h2>\n\n\n\n<p>The project required coordinated redesign across several engineering domains:<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">1. Protection Architecture Redefinition<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Migration from legacy protection logic to a structured, modern control architecture.<\/li>\n\n\n\n<li>Introduction of a software-based circuit breaker pattern for controlled fault isolation and recovery.<\/li>\n\n\n\n<li>Integration of hardware-based fault interruption with software-level resilience concepts.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">2. Electronics Redevelopment<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Development of a new protection controller with high-speed monitoring and control circuits.<\/li>\n\n\n\n<li>Redesign of the PCB layout using professional ECAD environments.<\/li>\n\n\n\n<li>Optimization of high-current routing and signal integrity for improved electromagnetic compatibility (EMC).<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">3. Mechanical Reconstruction<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Reverse engineering of the existing housing and actuation system.<\/li>\n\n\n\n<li>Redesign of mechanical components to improve maintainability and thermal behavior.<\/li>\n\n\n\n<li>Simulation of tripping and actuation mechanisms to validate functional reliability.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">4. System Integration Constraints<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Mechanical compatibility with existing power distribution cabinets.<\/li>\n\n\n\n<li>Retrofit capability without major modifications to field wiring.<\/li>\n\n\n\n<li>Minimization of installation downtime.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Implemented Solution<\/h2>\n\n\n\n<p><a href=\"https:\/\/www.shop-tps.com\/shop\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">TPS Elektronik<\/a> delivered a complete system redesign covering electronics, firmware, and mechanical construction.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Electronic Design and PCB Layout<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Development of a new protection control board.<\/li>\n\n\n\n<li>Structured PCB layout in modern ECAD tools (including Altium Designer and Cadence Allegro environments).<\/li>\n\n\n\n<li>Optimization of high-current paths and signal separation to support EMC performance.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Embedded Software and FPGA Control<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Implementation of protection logic using FPGA-based control architecture.<\/li>\n\n\n\n<li>Deterministic fault detection and fast signal processing.<\/li>\n\n\n\n<li>Application of a circuit breaker software pattern in firmware and distributed monitoring software to isolate faults and maintain system stability.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Mechanical and Enclosure Design<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Reconstruction of the breaker housing and actuation system using 3D CAD tools (e.g., SolidWorks).<\/li>\n\n\n\n<li>Thermal and mechanical validation of moving components.<\/li>\n\n\n\n<li>Design adjustments to facilitate servicing and long-term maintainability.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Retrofit Integration<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Mechanical and electrical integration into existing panels.<\/li>\n\n\n\n<li>Preservation of field wiring wherever possible.<\/li>\n\n\n\n<li>Structured validation prior to commissioning.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Project Outcomes<\/h2>\n\n\n\n<p>The modernization enabled the customer to continue operating its installed infrastructure while updating the protection platform.<\/p>\n\n\n\n<p>Observed improvements included:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Alignment with current industrial protection and monitoring requirements.<\/li>\n\n\n\n<li>Improved EMC behavior through optimized PCB routing and layout separation.<\/li>\n\n\n\n<li>Structured software fault handling to reduce the risk of cascading system disruptions.<\/li>\n\n\n\n<li>Extension of product lifecycle through retrofit integration.<\/li>\n\n\n\n<li>Reduced protection response time through FPGA-based signal processing (measured improvement compared to the legacy design).<\/li>\n<\/ul>\n\n\n\n<p>All improvements were validated within the project scope and documented in coordination with the customer.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Conclusion<\/h2>\n\n\n\n<p>This project demonstrates <a href=\"https:\/\/tps-elektronik.com\/en\/contact\/\" type=\"page\" id=\"1154\">TPS Elektronik<\/a>\u2019s ability to execute multidisciplinary modernization projects in the field of industrial protection systems.<\/p>\n\n\n\n<p>By combining:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Electronic system redesign<\/li>\n\n\n\n<li>FPGA-based embedded control<\/li>\n\n\n\n<li>Mechanical reconstruction and validation<\/li>\n\n\n\n<li>Structured software resilience concepts<\/li>\n<\/ul>\n\n\n\n<p>TPS Elektronik supported the transition from a legacy protection platform to a scalable and maintainable system architecture.<\/p>\n\n\n\n<p>The retrofit approach allowed the customer to modernize existing installations while preserving core infrastructure, reducing operational disruption during 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.wpforms-container -->","protected":false},"excerpt":{"rendered":"<p>This case study outlines the modernization of a legacy industrial circuit breaker platform, including PCB redesign, FPGA-based control implementation, mechanical reconstruction, and retrofit integration into existing power distribution cabinets.<\/p>\n","protected":false},"author":6,"featured_media":7273,"template":"","class_list":["post-7272","case_studies","type-case_studies","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Retrofit Circuit Breaker Design &amp; Panel Modernization | TPS Elektronik<\/title>\n<meta name=\"description\" content=\"Case study on modernizing an industrial circuit breaker system with FPGA control, PCB redesign, and retrofit integration.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, 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