Mimic Training Control Desk for a UK Defence Engineering Organisation
Sector:
Aerospace & Defence
Type:
New Build - Control System, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed and built a standalone mimic control desk system for a UK defence engineering organisation, replicating an operational control system for training purposes. The system uses Siemens ET 200SP distributed I/O and a Siemens S7-1200 PLC, communicating with an external training environment controller via DMX protocol, and was supplied complete with custom mechanical layouts, a full electrical drawing pack, FAT, and site installation support.
Challenge
The customer required a control desk that closely replicated the appearance and behaviour of an operational control system, to be used for training purposes. The desk needed to present operators with a realistic panel of indicators, buttons, gauges, and controls.
The system had to interface with an external training environment controller using DMX communications, support a range of digital and analogue I/O signal types, and be designed for easy relocation — requiring lockable castors and a bulkhead plug arrangement for straightforward connection and disconnection. A telephone port was also required on the desk.
Solution
DelaControl designed and built a standalone mimic control desk assembled from Rittal console and pedestal enclosures, housing a Siemens S7-1200 PLC with Siemens ET 200SP distributed I/O modules providing digital input, digital output, and analogue output capability. A USB-to-DMX interface (ETC Gadget II) provides the DMX RS232 communications link to the external BITE training system. A Siemens SITOP 24 V/20 A power supply with selectivity module provides the internal 24 V DC supply, fed from a single-phase 240 V mains inlet. An 8-port unmanaged Siemens switch supports PROFINET communications between the PLC and ET 200SP interface modules.
The operator panel is populated with Schneider XB6 series IP65 illuminated pushbuttons and panel-mounted LED indicators in multiple colours, alongside cam switches, rotary selectors, analogue ammeters, and XLR and 3.5 mm audio jack connectors. ILME modular multi-pin connectors are used throughout for the bulkhead plug arrangement, enabling fast and reliable connection and disconnection of the desk. Lockable castors are fitted to support easy repositioning.
DelaControl produced a full documentation pack including general arrangement drawings produced in AutoCAD Inventor, electrical schematics in AutoCAD Electrical or Eplan, a Declaration of Conformity to LVD and EMC directives, thermal calculations using Rittal Therm software, and an Inspection and Test Schedule. The panel was subject to internal pre-delivery testing followed by a Factory Acceptance Test with the customer in attendance at DelaControl's Bristol facility, prior to delivery and site installation support.
Key Facts
• Siemens S7-1200 PLC with Siemens ET 200SP distributed I/O across multiple PROFINET interface modules
• 32 Weidmuller solid-state interface relays for output signal conditioning
• DMX (RS232) communications interface via ETC Gadget II USB-to-DMX converter
• Siemens SITOP 24 V DC / 20 A stabilised power supply with selectivity module
• Schneider XB6 IP65 illuminated pushbuttons and indicators in red, green, yellow, and white
• ILME modular multi-pin bulkhead connectors for quick-disconnect panel interconnection
• Rittal console, desk, and pedestal enclosures with lockable castors for mobility
• Analogue panel ammeters (20 mA DC) and cam/rotary switches included on operator desk
• Full documentation pack: GA drawings, schematics, Declaration of Conformity, FAT schedule and certificate, thermal calculations
• Site installation support included