Electrical Enclosure Design (LUL)

We were asked by our client to provide a complete mechanical design and electrical system integration of a 2.5MW DC supply for their client London Underground Limited (LUL). The Unit was to be installed at Bethnal Green Tube station London.

The enclosure design needed to accommodate our customers electrical design & integrate with LUL site mechanical and electrical interface. Our client provided us with a detailed scope of work which included

  • Creepage and Clearance,
  • Ventilation, and IP Rating Requirements.
  • Electrical and Mechanical Interface Requirements.
  • Material Compliance Requirements.
  • Safety Requirements.

This enabled us to make good progress with the mechanical outline of the cubicle. Once we had an outline cubicle design we then started to work closer with our customers electrical Engineers on the system integration as this was least risk under a tight delivery schedule.

The enclosure consisted of an integral control unit and heat-sink stack with a variety of other electrical components resulting in a double enclosure joined in the middle sitting on a integral plinth. This also made site installation easier and reduced risk for site interface.

The enclosure design had to adhere to all LUL safety specifications such as low smoke zero halogen paint coatings and non metallic materials had to adhere to UL94/V0 fire and smoke specifications.



  • 3D Electrical Enclosure Design – Pro Engineer
  • Finite Element Analysis (External Support)
  • Design Reviews
  • Sheet Metal Detailed Drawings
  • Suppliers & Customer Liaison
  • Project Management
  • Manufacturing Support