Modular Power System

Goodwin Product Design carried out all the engineering and design for manufacture on the unique Flexo Modular Power System plug and socket industrial power cable system for BICC General Cables. The product enables contractors to install lighting and electrical power systems in a fraction of the normal time, it is designed for harsh environments and consists of a modular power cable with factory installed outlets. These plug in connections eliminate the need to install on site junction boxes.

Flexo is engineered from plastics designed to survive fires up to 950C and is sealed to IP67. It can be used on cables with diameters of 2.5-50 mm and up to 6 conductors. To reduce the overall size, the plugs are designed so that they can rotate to optimise the position of the lead cable. Flexo is used in the Channel Tunnel to provide power for the emergency lighting. Not surprisingly, it has had to pass stringent, fire, mechanical, electrical and environmental tests.

FLEXO is delivered on a drum containing a cable harness, which is simply unwound where it is required, for example along a tunnel wall. Once the harness has been supported on a tray, fixing the light fittings or other components, becomes a simple plug and socket arrangement, minimising the amount of site time consumed by installation, testing and commissioning.

Goodwin Product Design produced the initial design concept and handled the engineering and production of the product from rapid prototyping, right through to materials specification and component detailing for final mass production.