Control Panels of which you can be proud

CMRS Clinic Oct 2015

Jim Ironside

18 Oct 2015

Aim

An approach to making professional looking

control panels

Over-engineering – thy name is Ironside

The Big Picture

• Determine a need

– Not a solution

– Have a critical reviewer

• Design and test a solution

– If non-trivial or new, testing (in simulation/ mock-up/ prototype) saves rework

– Have a critical reviewer

• Build it

– And learn by doing (it is a curse)

Analysis not needed . . . .

• For a simple toggle turnout control

• For an on/off switch

• For most non-complex situations

BUT • Thinking about the User’s (not just the Builder’s)

needs is always valuable

Example: Programming Track

Solution: - Inset panel - Track state indication - Toggle protection - Inset relieved for visibility

Need: - On-layout programming track - Isolating section between programming and main tracks - Clear indication

Example: Shoo-Fly

Solution: - Inset panel - Mimic Diagram - Toggle protection - Dimmed LED indicates turnout moving - Inset relieved for visibility

Need: - Visual control and indication of track route

Example: Yard Panel

Need: - Clear indication of turnouts and tracks - Dismountable

Solution: - Toggles on photo of yard - Removable panel - Maybe not quite ready

(Concept Exploration Model)

Example: Ladder Control Panel Solution: - External panel in box - Mimic diagram - Route selection - Protected in transport

Need: - Easy for casual operators - Both module sides - Removable, Portable

Materials – no big deal

• Overlays – Paper

• Panel back – Sheet Styrene 0.125”

• Container (if needed) – Plywood

• Bond drill template to panel – Glue Stick

• Bond graphics to panel – Glue Stick

– White/ Yellow Glue

– Varnish

– Contact Cement

• Protective covering – Packing Tape

– Varnish

– Laminate

• Controls and Indicators – LEDs

– Buttons

– Switches

– Wire

Main Tools – no big deal

• Computer with Printer – PowerPoint

• Panel design

• Drill templates and overlay

• Partial simulation (if needed)

– Excel (if needed) • Full simulation and logic

testing

• Saw (preferably table saw) – For container

• Knife or Router – For inset panel

• Drill (preferably drill press) – For making panel

• Plastic wood – Most faults can be hidden

under patching and paint

Designing with Office

• PowerPoint – For most panels, can design and print full size

– Good control of colours and locations

– Allows integration of graphics and photos

– Can create grouped objects and reuse them

– Does not handle object changes well – global changes not possible

– Allows limited animation

• Excel – allows complete simulation of lights/ switches but at a cost in

appearance

Panel Design – Factors

• Usability

• Legibility

• Component space

• Finger space

• Wiring

Use photos of components in mockups where appropriate

Original Concept Turnout level control

Too many buttons

10 button concept Ladder sides not linked

201

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208C 207T

208T207C 206C 205T

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206T 205T

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204T203C 202C 201T

204T 203T

204T 203C 202T 201C

201C 202T

Indicates Turnouts Closed or Thrown by this button

Better, but . . ..

10 Button Concept Ladder sides linked with additional button for

opposing direction crossover

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Indicates Turnouts Closed or Thrown by this button

208C 204T 203C 202T

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Identical Function

Identical Function

Getting Closer

Possible future: perhaps too much to contemplate

Bit much

10 Button Concept Ladder sides linked with additional button for

opposing direction crossover

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Almost

8 Button Concept Ladder sides linked

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206T 205T 201C

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208C 204T 203T

208C 204T 203C 202T

201C

Indicates Turnouts Closed or Thrown by this button

208C 204T 203C 202T

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208T 207C 206C 205T

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Not Yet

Through Track Yard CFM_Ironside_150726

LY Main

LY 6

LY 7

LY Main

LY 4

LY 5

LY 3

LY 2

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205C

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208C

Lindsay Yard Ladder Calgary Free-mo Operator Notes:

Green tracks No parking

Through trains

NOT to be selected while trains

in either ladder

DT400 Route Switch [Number]

Closed

Crossover

Final Design

Electronics Design - factors • DCC or not

– Local control should always be available – Should users be able to control from a distance? – Is wiring simpler with DCC? – Is cost worth it?

• Routes or turnouts – Turnouts are easier for casual users to understand – Routes are easier for experienced users to use – Graphics can make the difference

• Power source – AC/ DC? Embedded or separate? – Does it need to be active independently of track power?

• Wiring complexity – Trade-off between user experience and build/ maintain

complexity

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205 LY5

LY3 LY7

LY2 LY6

LY Main LY4

LY Main

System Block Diagram

Lindsay Yard Ladder Section

Tor-toise

Tor-toise

Tor-toise

Tor-toise

Tor-toise

Tor-toise

Tor-toise

Tor-toise

Turnout Actuators

DS64 DS64 Command Station and

Boosters

Control Panel

Control Panel

Pwr Supply

Turnout Commands Sent/ Rec’d

Turnout Commands Rec’d

DT 400

Turnout Commands

Sent

Dual Frog Juicer

To Frogs Dual Frog

Juicer

Dual Frog Juicer

Dual Frog Juicer

LocoNet

Track Bus

Accessory Bus

Front Panel 8x Buttons plus switched 0 VDC

+12/ 0 VDC

LocoNet

0 VDC Switched SRC 0 VDC

LocoNet

+12/ 0 VDC

2C

SRC8

6p6c TB

2x10C

2x1

0C

Lindsay Yard Ladder Control Panel

External Connection

Panel

2C

6p6c APP2

16x Turnout States plus +5/ 0 VDC

Panel System Diagram

Button Kill

Container Design – Factors

• Usability – Consider how user will interact –

reach, obstructions

• Component protection – Components should not be

susceptible to damage in use or transport

• Ease of construction – Tool setups, assembly constraints

– Trade-off with usability

• Ease of maintenance – Access/ remove components for

support

Mock-up/ Simulate/ Prototype

• Mock-up – Printouts taped to fascia

– Three dimensional cardboard mock-ups with printed faces/ some real components

– Leave them in your peripheral vision to stew

• Simulate – Only for complex panels

– PowerPoint – realistic but limited capability

– Excel – less realistic but more complete emulation

• Prototype – Physical similarity to final design, to discover build issues

Mock-ups Tape them up and look. Many alternatives to consider!!

Viewing paper mock-up on fascia changed

this to

this

Simulations - PowerPoint • Good visual fidelity – actual panel graphics

• Limited functionality

– Flip between slides – only buttons in squares active

– No logic statements behind graphics

• A bit nerdy

Simulations - Excel • Less visual fidelity

• Powerful logic control via equations and macros

• Good for assessing/ testing control logic eg route and indicators

• Very nerdy

Be prepared to do it twice!!

• The builder’s version of the Chinese curse:

“May you learn by doing”

• Prototypes and simulations help keep it from being three or four times

Prototype Ogden Yard Panel Photo background on panel

Turnout wiring through TB to adjust Closed/ Thrown polarities Cardboard mounting mock-up

?

Prototype – Lindsay Yard Panel Turnout approach to buttons Colour and spacing Graphic bonding using varnish

200-ish soldered connections Separate boards for LED Resistors Standoff electronics mounting

Making it – the big picture

• Make Container

– Cut parts

– Assemble

– Finish

– Make other components (eg connector panel)

– Wire (as needed)

• Assemble panel to container

• Make Panel

– Make blank to fit container

– Drill using drill template

– Bond graphic

– Cut holes in graphic

– Populate

– Add additional structure (eg electronics board supports, wire strain relief)

– Wire

– Test

Container Build

• Mostly basic carpentry – Consider assembly when designing

– Plan cuts to make identical parts with a single tool setup (fences, angles, etc)

– Use plastic wood to fill gaps

– Finish with paint to hide plastic wood

Never underestimate the ability of plastic wood and paint to hide

mistakes!!!

Panel Build Preps

• Confirm Panel Size

– Container tolerances!!!!

• Drill pattern

– Simplified version of panel design to locate holes in panel

– Separate from final overlay because of additional detail, and because drilling tends to tear it

• Overlay

– Very simplified version with only the residual graphics

Through Track Yard CFM_Ironside_150726

LY Main

LY 6

LY 7

LY Main

LY 4

LY 5

LY 3

LY 2

201C

202C

203C

204C

205C

206C

207C

208C

Lindsay Yard Ladder Calgary Free-mo Operator Notes:

Green tracks No parking

Through trains

NOT to be selected while trains

in either ladder

DT400 Route Switch [Number]

Closed

Crossover

Drill Pattern

Through Track Yard CFM_Ironside_150726

LY Main

LY 6

LY 7

LY Main

LY 4

LY 5

LY 3

LY 2

201C

202C

203C

204C

205C

206C

207C

208C

Lindsay Yard Ladder Calgary Free-mo Operator Notes:

Green tracks No parking

Through trains

NOT to be selected while trains

in either ladder

DT400 Route Switch [Number]

Closed

Crossover

Panel Graphic

Panel Build (1) Drill blank

• Cut blank – Make it match container!!

• Bond drill pattern to blank – Coat of varnish on pattern

will make it less fragile when moved on blank to align

– Use water soluble glue, eg glue stick – you will remove it later

– Ensure alignment with edges of blank – tricky – easier if pattern is trimmed to blank size so that edges can be aligned

• Center mark – Cross lines in drill pattern are

centre points

• Pilot Drill – Small drill will ‘find’ the

centre marks better

• Drill – Use correct size drills for

close fit to components

– Drill pattern indicates different drill sizes

• Remove pattern – Soak and scrape

Home Reading

Panel Build (2.1) Bond graphic overlay to drilled blank

Three methods: • Glue and Tape:

– Overlay bonded to blank with glue, and protected by clear tape – Suitable for smaller panels

• Varnish

– Overlay bonded to blank with crystal clear varnish, then sealed with one or more additional coats of varnish

– Suitable for medium size panels; getting a full bond can be tricky

• Laminate

– Overlay laminated (Stapes etc); laminated overlay bonded to blank – Suitable for all panel sizes

• All Methods: – Pre-seal overlay (except laminate) with light coat of crystal clear varnish – Sand drilled blank to give surface some ‘tooth’ – Anticipate some shifting of overlay to position properly; eg not contact cement – Anticipate scraping it off and trying again on your first couple of attempts.

Home Reading

Panel Build (2.2) Bond overlay graphic to drilled blank

Glue and Tape Method: • Coat blank with thin coat of medium-slow

drying (to get time to adjust) glue (white/ yellow glue or glue stick works)

• Hold drilled blank to light (light box is good) and align overlay with holes

• Press down firmly and repeatedly until glue sets up enough to hold. Placing face down on foam with weights to press it will help get good overall bond

• When dry, trim overlay to edges of blank • When fully dry, cover surface and wrap

around edges with clear packing tape to protect.

Varnish Method: • Coat blank and overlay with a thick-ish

layer of Crystal varnish • Hold drilled blank to light (light box is

good) and align overlay with holes • Press together and squeeze excess varnish

towards edges • Press down firmly and repeatedly until

varnish sets up enough to hold. Placing face down on foam with weights to press it will help get good overall bond. Use plastic sheet between foam and panel!!

• When dry, if bond is not complete at edges, flow more varnish into gaps and press etc

• When dry, trim overlay to edges of panel • Add one or more coats of varnish to seal

permanently

Home Reading

Panel Build (2.3) Bond overlay graphic to drilled blank

Laminate Method:

• Have panel graphic overlay laminated between clear sheets (Staples, etc)

• Coat blank with thin coat of latex contact cement. Do not allow to dry!!!

• Hold drilled blank to light (light box is good) and align overlay with holes

• Press down firmly and repeatedly until glue sets up enough to hold. Placing face down on foam with weights to press it will help get good overall bond

• When dry, trim overlay to edges of blank

Cut holes:

• Using sharp knife with sharp tip (X-Acto #11 blade or equivalent) cut out overlay to edges of holes – carefully, you do not want to get blood red all over it.

• Test fit components; clear holes with twist drill by hand if necessary

• Using drill from back of panel poses less risk of breaking overlay bond to panel

Home Reading

Panel Build (2.4) Finish Blank

Cut holes:

• Using sharp knife with sharp tip (X-Acto #11 blade or equivalent) cut out overlay to edges of holes – carefully, you do not want to get red all over it.

• Test fit components; clear holes with twist drill by hand if necessary

• Using drill from back of panel poses less risk of breaking overly bond to panel

Add other infrastructure

• Populate all components likely to affect positions of stand-offs, strain reliefs, etc

• Glue electronics stand-offs, cable guides, etc in place

• Add remaining components

• LEDs or other press fit components should be secured with a drop of Superglue (or nail polish) from back of panel

Home Reading

Panel Build (3) Wiring

Guidelines for final wiring: • Design wiring layout for maintenance • Organize wires systematically as much

as possible • Use colour codes to distinguish

different wire functions • Use connectors between major

assemblies to allow construction at the bench, and removal for maintenance or access

• Use the smallest wire possible – it gets congested back there

• Use strain reliefs to ensure pigtails do not pull on components

• Wire and test to ensure good connections to the proper components

• Insulate bare connections where there is risk of short circuits

Guidelines for Testing • Micro-clip leads, with alligator clips on

the other end, are an essential tool • Test components (eg LEDs, buttons)

before installation – it is easier to replace them before they are installed

• Some pre-assembly (eg resistors on LEDs) can be done prior to installation

• Check soldering for cold joints • Start with continuity testing • Check shorts between connector pins • Use a battery to test LEDs from

connector pins before connection to electronics

• Check polarity of power feeds • Plug in electronics and let the smoke

out

Home Reading

Assemble

Photo of assembly open

Summary

• Good control panels make layouts easier and more fun to operate

• A good panel considers the user needs first, the builder needs second

• A thoughtful process can deliver good-looking panels that do the job you need them to do

• Building a panel of which you can be proud is a satisfying part of the hobby

Full presentation will be on the CMRS Website Or E-mail me at IronsideJim@gmail.com E-mail address also in the OrderBoard