Why Panel Builders Are Turning to Virtual Prototyping and Automation

Closing the Gap Between Design and Production

Are your electrical design teams and control panel building teams worlds apart? As an Engineering Manager, you probably feel the need to keep an eye on how your colleagues on the shop floor are bringing your designs to life. When two-dimensional schematics are passed from the engineering department to production, errors can quickly crop up as certain useful information is missing.

Where exactly do components need to be placed on the mounting plate? Is it clear where the drill holes need to be cut out? And the operating elements on the door? Where should the cable ducts, DIN rails and terminals be installed? If there aren’t any exact specifications, various queries from the production team and the client are inevitable.

What is Virtual Prototyping?

Virtual prototyping is the process of creating a full 3D digital model of a control panel before any physical work begins. This model, often referred to as a digital twin, includes the exact placement of components, wiring routes, cable ducts, and mounting holes.

By simulating the entire panel build virtually, engineering teams can detect design flaws early, optimise layouts, and generate all the necessary production data—saving time, reducing errors, and streamlining the handover to manufacturing.

From 2D Schematics to Intelligent 3D Design

Thanks to 3D design, Eplan can provide this information. 3D design is ready to combat the challenges and errors that come about from 2D schematics. Eplan's 3D capability gives design engineers all the tools they need to create complex and highly detailed digital twins for electrical control panels. The software allows engineers to visualise how components will fit into the panel, identify possible collisions, find the optimum wiring route and check to provide cooling to the potential hot spots.

Using data from the schematics created in Eplan, you can compile important information for materials procurement. Then, the Eplan project data is the perfect foundation for deriving a realistic digital twin of the planned control panel. The right 3D software makes it easier for both electrical engineers when designing the control panel, and for technicians when producing it.

The Difference Between 2D and 3D Panel Building

Where exactly are the components placed in the control cabinet? Does it all fit? With 2D schematics, there's no info about where cable ducts or bore holes should be placed. Assembly and cabling can only be realised by experienced employees. Every finished control cabinet looks different, despite being produced in series. Overall, this results in more questions than answers, wasting both time and precious resources.

Panel building with a 3D model is a very different experience. All components are already positioned on the mounting plate and displayed realistically. The entire structure of the control cabinet is clearly described. Understandable visualisations support co-ordination and project approvals. Production assistance tools can guide even inexperienced workers through mounting and wiring. Overall, this results in a virtual prototype for fast panel building and a smooth approval process.

4 Key Benefits of Virtual Prototyping

1. A Better Product

By combining engineering and panel building within virtual prototyping, you bring the knowledge of the panel builder closer to the customer. Involving the panel builder early in the process enables him to bring all his knowledge alongside the customer's proposed changes is what will lead to a better product.

2. No Unpleasant Surprises

Virtual prototyping allows you to show the customer a 3D design of the enclosure much earlier in the development process. Instead of a photo after that, the customer sees what the cabinet will look like in advance. The customer can then give their feedback before the cabinet is built.

3. Lower Costs

Thanks to virtual prototyping, any design errors can be detected and corrected at a much earlier stage. This is of course much cheaper than making changes on the shop floor later. In addition, virtual prototyping is much faster and therefore much cheaper than the traditional method of cabinet layout in the workshop.

4. Perfect Documentation 

In traditional panel building, last-minute changes often do not appear on the final drawing. With a bit of luck, an 'as built' picture will be added to the documentation. With virtual prototyping, you are ahead of this. The 3D model of the cabinet can be easily adapted, preventing the need for later changes in the workshop. The customer will also receive a drawing that is 100% in line with reality.

Automated Panel Production

By creating a highly accurate digital twin early in the process, virtual prototyping can  improve design and documentation while also the groundwork for seamless automated panel production.

Are your order books full, but it's a struggle to complete existing projects? Often this is because it's not easy to find qualified personnel, especially for highly technical jobs in panel production, such as wiring. Perhaps the company would love to take on more business, but long-term employees already have their hands full doing day-to-day work for control panel assembly.

Between drilling patterns, crimping cables and wiring according to the electrical schematics, there simply isn’t time for taking on additional projects. At the same time, clients are turning up the heat: both volume production and highly customised production for one-of-a-kind items must be delivered as quickly as possible.

3D Models, Assistance Applications, Automated Machinery 

If your design department plans control panel layouts in 3D, the data from the engineering designs can serve as the technical specifications for production equipment. For instance, mounting plates can be drilled fully automatically, or cables routed in 3D can be cut-to-length and crimped. This reduces errors, and vastly reduces work times; making happy customers and increasing order capacity. 

Easy Control Panel Assembly

• Easily generate manufacturing drawings and cutting lists for cable ducts
• Use 3D routing to determine cable lengths
• Use equipment for component labelling or automatic crimping machines
• Step-by-step guides for cabling and component placement based on 3D data
•  The 3D model supplies lists and instructions for production
  

Automated Panel Production

• Use the data for order processing and production management
• Seamless data transfer to manufacturing machines for automated cabinet modification
• Automatically cut, crimp and bundle cables using data from the 3D model
• The 3D model delivers the data ready for the automated manufacturing machines
  

Case Study: LCA Group

At LCA Group, the Eplan software interfaces directly with Rittal’s advanced manufacturing systems. These include the Rittal Perforex laser processing centre, a system for manufacturing sheet-steel panels.

The LCA Group takes on a “Man vs Machine” challenge which compares traditional panel building with a fully automated workflow. The result? A striking demonstration of just how much time and effort digitalisation can save.

Using Eplan Pro Panel and Rittal’s Perforex machine, the automated process significantly outpaced the manual build. With data-driven design, automated wire processing, and enclosure assembly, the digital workflow delivered faster results with fewer errors and less repetitive labour.

For manufacturers looking to streamline production, the message is clear: embracing automation isn’t just about speed; it is equally about smarter, more scalable project delivery.

You’ll even have time to read the latest magazines while you wait for the laser cutting to finish!

Watch LCA Group’s Man vs Machine video here.