Disc-Mounted Control Panel Suite for High-Performance Racing Simulator
Sector:
Motorsport
Type:
New Build - Control System
Platform:
Beckhoff
Certification:
CE / UKCA
Summary
DelaControl designed and built a suite of ten distinct control panel and backplate types — 31 units in total — to support the disc-mounted electrical systems of a high-performance racing simulator. The panels were built and tested at DelaControl's Bristol facility to IEC standards, with a full documentation package including electrical drawings, thermal calculations, and a Declaration of Conformity.
Challenge
A motorsport technology company required a complete set of disc-mounted control panels and backplates for a new racing simulator platform. The panels needed to cover a range of functions — I/O, servo drive interfacing, power distribution, safety braking, and UPS — across multiple identical disc assemblies.
The requirement was for a fixed-price, fully tested and documented build that consolidated all engineering changes accumulated during an earlier development programme, resulting in a definitive specification suitable for repeat production.
Solution
DelaControl built 31 control panels and backplates across ten panel types, covering functions including I/O processing (using Beckhoff hardware), axis drive interfacing, power distribution, safety braking control, and uninterruptible power supply. Some units were configured with quick-disconnect connectors rather than hard-wired cabling to simplify maintenance access.
All panels were manufactured at DelaControl's Bristol facility. Pre-delivery testing used I/O simulation test boxes and test motors to verify electrical correctness and functional operation before customer sign-off.
Documentation delivered with the panels included a full electrical drawing pack (general arrangements and schematics), thermal calculations performed using Rittal Therm software, a Factory Acceptance Test schedule and certificate, and a Declaration of Conformity confirming compliance with the Low Voltage Directive and EMC Directive under BS EN 60204, BS EN 61439-1, and BS EN 61439-2.
Key Facts
• 31 control panels and backplates built across 10 distinct panel types
• Beckhoff hardware used for I/O processing
• Low latency drives
• Lemo connector range adopted across multiple panel types
• Thermal calculations performed using Rittal Therm software
• Certified to IEC standards (LVD and EMC Directives); UL certification not required
• Factory Acceptance Test conducted at DelaControl's Bristol facility