Building an automation control cabinet (also known as a control panel or electrical cabinet) involves organizing and integrating electrical components that control machinery or processes. These cabinets are used in industrial automation to house PLCs (Programmable Logic Controllers), relays, motor drives, safety devices, HMIs (Human-Machine Interfaces), and more.

Here’s a step-by-step guide to building a typical automation control cabinet:

  1. Planning & Design

  • Define application requirements: What machines or processes is the panel controlling?
  • Create electrical schematics: Use software like EPLAN, AutoCAD Electrical, or SolidWorks Electrical.
  • Component selection: Choose PLCs, contactors, relays, breakers, VFDs, terminals, etc., based on specs.
  • Enclosure sizing: Calculate the heat dissipation, space requirements, and environmental protection (NEMA/IP rating).

  1. Cabinet Preparation

  • Mount DIN rails and cable ducts: Arrange for component accessibility and wire routing.
  • Cutouts & mounting: Drill or punch holes for HMI, push buttons, fans, etc.

  1. Component Installation

  • Install:
    • PLCs & I/O modules
    • Terminal blocks
    • Power supplies
    • Circuit breakers & contactors
    • Relays and timers
    • VFDs or servo drives
    • Communication modules
    • Ethernet switches (if networked)
  • Ensure good separation between high-voltage and low-voltage wiring.

  1. Wiring

  • Use color-coded wires: Typically, black for AC power, red for DC, blue for neutral, green/yellow for ground.
  • Label wires at both ends using ferrules or sleeves.
  • Follow wire routing through cable ducts.
  • Test continuity and insulation resistance.

  1. Thermal Management

  • Add cooling fans, filters, or A/C units if heat generation is significant.
  • Consider ventilation layout and heat sinks for drives.

  1. Testing & Commissioning

  • Power up the cabinet: Verify voltage levels.
  • Test all inputs/outputs to/from the PLC.
  • Simulate operation and check safety circuits.
  • Program the PLC/HMI and verify logic.

  1. Documentation

  • Include:
    • Electrical schematics
    • Component datasheets
    • Wiring diagrams
    • PLC and HMI program backups
    • Panel layout drawing
    • Maintenance manual