Back to Basics 2: Control Panels

In 1995 I started building control panels in my garage. I was still working for an electrical distributor at the time, and one way to make a sale was to provide a complete solution rather than selling individual components. Since I could also create electrical drawings, I was able to put together some packages for local companies.

Dry River Panel

Not all control panels needed a PLC. This one had a proprietary board that controlled a process that made extruded plastic fencing. There were a LOT of selector switches on the front of the panel that controlled zone heaters with the relays you see here. This company was a start-up and welcomed having an inexpensive way to get a panel fabricated.

Zellweger Panels

More panels without a PLC. These were build in 1999 side by side with a project for NAS, where we designed, built and programmed a system that transported cotton for the USDA. Zellweger Uster made the inspection stations and we contracted independently with them for fabrication.

As you can see, there was a PLC, a SLC 5/05. At this time, it was the single largest project we had taken on. There were only about 8 of us in my company including myself and my wife, and it pretty much took up all our resources for most of the year. The installation was in Memphis, about 370 miles from our shop in Knoxville.

My company ACS stayed open until 2006 when I moved here to Nashville. We built hundreds of control for NAS and other companies, and eventually also started building small machines. We looked into getting UL certified, but had enough business without it, and closed before doing so.

I don’t build many control panels anymore, but still design for others. While my wife has helped me by building some panels for ABD, she has pretty much retired also. I am still looking for interesting jobs and projects though; if you need help, no matter how small or off the wall your application, hit me up!