The client is an engineering company that designs and implements communication, automated control, and dispatching systems for power infrastructure facilities.

The task was to develop an ATS (Automatic Transfer Switch) device from scratch — a unit that monitors two independent power inputs and switches the load to the backup source upon loss of the primary. From the outset, the client set a number of strict technical requirements:

• Switching speed. Connected equipment must not register a failure.
• Compact dimensions. The device must fit into a 1U enclosure for mounting in a standard 19-inch rack while delivering a full feature set: network parameter measurement, event logging, self-diagnostics, and local and remote control.
• Operating temperature range. The device must function from +5 to +60°C, corresponding to conditions inside industrial enclosures without forced cooling.
• Series production readiness. The design must be suitable for serial manufacturing from day one of the design process.

The device is built on four independent modules: a base module, a communication module, a power module, and a power supply unit. The key architectural decision: the base module performs the switching function autonomously, even in the event of a communication module failure. This is critical for equipment that operates without continuous maintenance.

The power section is physically separated from the control electronics inside the enclosure — this is standard practice for industrial devices, where interference from power circuits can affect the measurement and communication sections.

Fitting a fully functional industrial device into a 1U height is first and foremost a mechanical design challenge. The electronic architecture sets the requirements, but it is the enclosure that determines whether they are physically achievable.

A 1U form factor in a 19-inch rack means 44.45 mm of height. At this height, the layout leaves no room for error: every millimeter is occupied, and the placement of each component affects its neighbors.

The main enclosure parts — the base and the cover — are made from sheet galvanized steel using laser cutting and bending. For rack-mounted equipment this is the standard: steel provides maximum rigidity at minimum sheet thickness. The front panel is the only aluminum part: it machines well, holds precise geometry, and adds no unnecessary weight where there are no mechanical loads.

The front panel is a milled faceplate with a recess for a membrane keypad. The recess serves a structural purpose: the keypad sits flush, is protected from mechanical damage, and does not peel off under vibration.

Within the front panel area of a 1U unit, a membrane keypad was fitted with separate zones: control and navigation buttons on one side, LED status indicators on the other. Plus a display, a speaker, and connectors. The layout of elements was developed around a specific operator workflow: read the status at a glance, operate without consulting documentation.

The rear panel houses terminals and short-circuit protection breakers. The division is clear: everything requiring cable connections on site is moved to the rear; everything the operator interacts with during operation is on the front.

Inside the enclosure, the power section is separated from the electronic modules by a partition.

The client received a functional prototype with confirmed performance characteristics: correct input switching, stable operation across the +5…+60°C range, and a complete communication stack.

The enclosure design and manufacturing technologies were selected with series production in mind. Laser cutting and bending ensure consistent tolerances without manual fitting — every unit replicates the first. The transition to serial production will require no changes to the documentation.

The modular architecture leaves room for further development: expanding functionality or adapting the device for adjacent applications means updating a single module, not starting a new project.

The result: a proprietary product with full control over the specification and independence from third-party equipment suppliers.