PLC Trainer
2025, Engineered Software
Engineered Software were looking to develop a user-friendly PLC training device for trainee machine programmers. The electrical components were specified and a preferred layout for the interface, so I was tasked with designing a simple enclosure. The process began with initial concept sketches exploring layout and form. These were refined into detailed 3D models, which ultimately informed a full set of technical drawings for prototyping and production.
PROCESS
Brief
The training device had several key requirements:
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The construction must be simple and cost-effective for low-volume manufacturing.
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It must be compatible with the specified hardware.
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It must use the pre-determined interface layout.
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It should be a rugged and reliable housing, with basic portability.
Design
The chosen design is a simple sheet metal body, with an angled, recessed face. The dark interface contrasts with the body and the illuminated display. It has large bend radii on the corners to soften the design. We chose to omit the carry strap and use embedded grab handles instead.
Designing the sheet metal enclosure was quite straight-forward. We had a few constraints to work with; avoid welding and excessive visible fasteners. To achieve this, I modelled the external panels with internal mating faces that can be riveted. These panel and the interface backplate mount to the base plate, allowing all but two fasteners to be hidden. All the control gear is supplied by Siemens. I sourced 3D models for all components, and integrated into the design.
After several revisions and approval of the design, I developed technical drawings for each part and specified requirements for manufacture. Engineered Software is now producing these for education institutions around the UK. Renders weren't required for this project, so these are just a quick output from Fusion 360.
PLC Trainer Lite
We also developed a 'lite' version of the trainer, by incorporating the control equipment into a durable off-the-shelf carry case.
You can check out another project I did for Engineered Software here.