What are DIN Rails?

When it comes to industrial control and automation, efficiency, organization, and standardization are all major concerns that influence system design and the implementation of technology. For many systems, the DIN rail serves as an essential solution for achieving such goals, these standardized metal racks and enclosures offering a robust system for attaching an array of electrical and electronic devices. In this blog, we will discuss DIN rails in more detail, covering everything from their developmental history to the common types that are available on the market. With this information, you can better approach procuring parts of need for operations, so be sure to read on.

A Brief History of DIN Rails

The DIN rail system was initially developed in the 1920s by the Rhine Westphalian Electrical Power Utility and Phoenix Contact, eventually becoming a rail option that was widely adopted across the globe by the 1950s as the Deutsches Institut für Normung (DIN) standardized specifications. The technology came about as a means of efficiently mounting electrical connections, making control cabinets and industrial environments much more organized with their modularity.

While DIN rails are mechanically passive in that they do not form a part of the electrical circuit themselves, they are essential because of their role in providing the necessary physical support for entire assemblies to function as intended.

The Unmistakable Advantages of DIN Rail Systems

The universal adoption of DIN rails stems from a collection of powerful benefits that legacy mounting methods simply cannot match.

• Time and Labor Efficiency: Components designed for DIN rail mounting typically feature a snap-on or slide-on mechanism, eliminating the need to drill and tap individual mounting holes for each component. This drastically reduces assembly time and labor costs for the benefit of operators.
• Superior Space Optimization: DIN rails enable high-density component layouts, as their design allows for devices to be mounted in tight, organized rows for engineers to fit more hardware into smaller enclosures. This has a dual benefit of saving physical space and reducing cabinetry costs.
• Enhanced Serviceability and Safety: A well-organized DIN rail layout simplifies maintenance and troubleshooting, as components are easily accessible and can be replaced quickly without disturbing adjacent devices. This orderly arrangement minimizes wiring confusion, reduces the risk of installation errors, and improves overall safety.
• Cost-Effectiveness and Standardization: Thanks to universal standards like IEC/EN 60715 and others, DIN rails and their compatible components are easily produced by numerous manufacturers worldwide. This competition and standardization ensure wide availability and competitive pricing, a benefit to all operators.

An In-Depth Look at the Major DIN Rail Profiles

While all DIN rails serve the same fundamental purpose, they are not a one-size-fits-all solution. In fact, these rails are organized into several standard profiles or cross-sections, each of which is suited for different applications and load requirements.

The TS35 Rail

The TS35 is the most prevalent type, offering a standardized and reliable design that performs optimally across many applications. The TS35 is notable for featuring a symmetrical, hat-shaped profile that offers excellent stability for a wide range of components, the rail being known as the “top-hat rail” for its unique design.

• Dimensions: The TS35 features a standard width of 35mm, while the depth may vary.
• Depth Options: The TS35 rail is available in two standard depths:
  • 7.5mm (35x7.5): This shallower version is ideal for mounting smaller and/or lighter components like terminal blocks, relays, and timers.
  • 15mm (35x15): The deeper rail option often provides greater structural rigidity and is most commonly used for organizing heavier or bulkier devices, such as power supplies, circuit breakers, and compact PLCs.

The TS32 Rail

Also called the "C-rail," the TS32 option is defined by its symmetrical, C-shaped cross-section and 32mm width. This rail is specifically engineered to support various applications with enhanced mechanical strength, its shape offering greater resistance to flexing and twisting forces. This makes it the ideal choice for mounting heavier equipment, with typical applications including supporting large transformers, robust power supplies, and other weighty components that would exert too much strain on a standard top-hat rail.

The TS15 Rail

Shaped like its larger TS35 counterpart, the TS15 is a more miniature rail with a width of just 15mm and a standard depth of 5.5mm. Its smaller profile makes it perfectly suited for compact applications that optimize the use of space. For example, one will often find these rails within small junction boxes and control consoles, as well as for mounting miniature components like sensor interface blocks and micro-relays.

The G32 Rail

The "G-rail" derives its nickname from its distinct, asymmetrical cross-section that is shaped like a “G,” this unique design provides two different mounting levels. The deeper channel is specifically engineered to offer superior support for heavy or high-powered components, preventing them from twisting or dislodging under heavy loads or vibration. Meanwhile, the shallower channel is used for lighter ancillary devices. This makes the G-rail an excellent choice for hybrid applications that mix heavy and light components on a single assembly.

How to Select the Right DIN Rail

Choosing the appropriate DIN rail for one’s particular application requires a quick but careful assessment of all system needs and relevant operational factors.

Step 1: Analyze Component Load

The first thing one should make before purchasing a DIN rail is determining the weight and size of the devices they need to panel mount. For standard control components, a TS35 rail is usually sufficient, while large transformers, power supplies, and other heavy items may necessitate the use of a more robust option.

Step 2: Evaluate the Installation Environment

Next, be sure to consider the operational environment that DIN rails and equipment will be placed in. Most DIN rails are made from zinc-plated, passivated steel, which offers good corrosion resistance for typical indoor applications. However, for environments with high humidity, chemical exposure, or for food-grade applications, stainless steel or aluminum rails are the more recommended choice.

Step 3: Consider Materials and Standards

Ensure the rail you choose conforms to all relevant international standards (e.g., IEC/EN 60715) to guarantee compatibility with parts and compliance with industry regulations. This will also eliminate sourcing risks and ensure a perfect fit regardless of the component manufacturer.

Where You Can Secure DIN Rail Parts with Ease

Whether you are interested in DIN rail assemblies or the electronic parts that are organized within, look to Just Connectors for all your operational needs. As an ASAP Semiconductor purchasing platform, customers have access to over 6 billion parts that have been sourced from leading manufacturers across the globe. All of these offerings can easily be searched with our curated catalogs and simplified lookup tools, so take your time narrowing down all that your operations require. Our industry experts would be happy to provide tailored options by phone or email, so do not hesitate to reach out once you are ready to kick off fulfillment!

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1. nicholas smith
2. Posted on July 16, 2021
din connectors

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