Precision in Design: Specifying Large Handheld Enclosures for Industrial Electronics

The growing sophistication of machine control, robotics, and factory automation is driving demand for larger handheld devices. However, selecting the appropriate housing for these devices presents designers with significant challenges.

When designing handheld electronics, ergonomics plays a vital role — especially when the device exceeds the size of a typical human hand. The casing must be spacious enough to house the necessary components while remaining comfortable for prolonged use.

The distinction between ‘handheld’ and ‘portable’ is subtle. If an enclosure is too large, users may find it convenient to carry, but far less appealing to hold and operate for extended periods.

The housing must be curved and tactile but still have a large flat operating area for a touch screen, membrane keypad or front panel assembly — along with other surfaces for buttons or connectors. And then there are the questions of robustness and ingress protection.

In a market dominated by phone-sized enclosures and remote control fobs, sourcing a larger housing suited for demanding industrial environments can be a challenge.

Fortunately, purpose-built plastic enclosures exist, designed to meet the rigorous technical standards required in factory settings. They maintain a discreet, adaptable aesthetic while incorporating the essential features needed for specialised applications.

These enclosures address ergonomic concerns through a well-balanced design with a comfortable grip, ensuring usability even when the expansive display surface extends beyond the grasp of a typical human hand.

This design ethos is exemplified by HAND-TERMINAL (IP 65 optional), a large machine control enclosure available in two versions — one for membrane keypads, the other for front panel assemblies. The back is contoured for comfort while the top is flat. There is space for buttons on the sides while the front is recessed to protect connectors.

Virtually all standard enclosures — handheld or otherwise — will require some form of customisation but the larger the range, the less machining is needed. This is the case with DATEC-MOBIL-BOX (IP 65 optional); it is available in multiple versions to suit a range of displays including Type 2″-LC-Glass, Type 2 x 16 (standard or compact), Type 4 x 16 standard, Type 2 x 20 miniature and Types 4 x 20.

Power is always a crucial consideration so any larger handheld enclosure should offer the choice of either a cable or a battery compartment, preferably with a wide selection of cell configurations.

DATEC-CONTROL — which is designed to house larger display modules — has a large rounded head that is counterbalanced by a long body which (depending on size) can accommodate 2, 3, 4, 5 x AA or 1 x 9 V batteries, along with PCMCIA holders.

In the past, many standard enclosures were moulded from ABS. It is a tried and trusted all-round plastic with high tensile strength and good resistance to chemicals. However, industrial applications call for something tougher — such as a polycarbonate/ABS blend.

Meanwhile, UV stability is a must for outdoor use. Enclosures such as DATEC-COMPACT (IP 65) are moulded from UV-stable ASA+PC (UL 94 V-0) in preference to ABS. These enclosures are aimed at applications including mobile data recording, measurement and control, environmental technology and Industry 4.0. Many will be used outdoors. So — on versions with a battery compartment — SD cards and USB connectors can be inserted within the sealed area for added protection.

When selecting standard enclosures, it’s essential to consider the necessary accessories. For mobile devices, this includes battery compartments, holders, clips, contacts, and spacers. You may also require a docking station for charging and data transfer or a wall-mounted holder.

For cable-connected devices, options such as cable grommets and strain relief clamps help ensure durability. Additionally, soft-touch protectors offer impact absorption, providing extra protection in demanding environments.

A good enclosure manufacturer will offer to assemble the accessories as a custom service. Other customisation options include CNC machining, lacquering, decor foils, printing of legends, logos and photo-quality graphics, special materials (such as bespoke colours or V-0 plastics) and EMC shielding.

Choosing a single-source manufacturer that can carry out a full range of customisation services in-house ensures quality and accountability. It also saves money, shortens delivery times and reduces administration.

For more information, view the OKW website: https://www.okw.com.au