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Operator Case Build — Custom I/O Panels and Cable Pass-Throughs

CONFIRMED ALL RIGS

Summary

Community operators build custom Pelican / road cases for their motion-control setups, incorporating internal transformers, mains distribution, and cable pass-through panels. A recurring topic is how to build a reliable operator case with neat pass-through panels for Ethernet, SDI, triggers, and power connectors, and how to extend short cables (such as the laser bloop light) to reach the case from the camera position.

Common Case Build Topics

Umbilical Opening / Lid Pass-Through

When the main umbilical connects to the robot at the front of the case:

  • Route the umbilical through a purpose-cut opening in the case lid or side panel.
  • Seal around the opening with foam or grommet material to protect the cable and maintain some dust/splash protection.
  • A transformer inside the case (for mains conversion or isolation) requires adequate ventilation — do not seal the case completely during operation.

D-Type / XLR / Neutrik Panel Connectors

For a permanent I/O panel on the case lid or face:

  • D-Sub (D-Type) pass-through connectors are the standard approach for keeping cables short inside the case. Female on the outside, male on the inside, with a short flying lead to the equipment.
  • Neutrik PowerCon was suggested for mains pass-throughs — these are locking AC connectors that prevent accidental disconnection.
  • Neutrik EtherCon (ruggedised RJ45 with locking body) is recommended for Ethernet pass-throughs — standard keystone inserts can unplug too easily.

Ethernet Cable Grade — CAT5e vs CAT6

From a 2026 community discussion about pass-through panel design:

  • CAT5e is sufficient for all Flair / InTime / robot control applications. The bandwidth requirements are well within CAT5e's capability.
  • CAT6 provides a larger cable diameter and is stiffer — this can make routing inside a case harder, especially through tight bends.
  • Use CAT5e with Neutrik EtherCon connectors for a reliable, manageable build.

Adding Ethernet, SDI, and Trigger Connectors to an Operator Case

From the 2026-03-31 to 2026-04-01 community thread:

  • A typical operator case panel includes: 1–2 Ethernet ports (EtherCon), 1–2 SDI BNC, and trigger/sync connectors (3.5 mm TRS or XLR depending on what the rig requires).
  • For trigger/sync: a 3-pin XLR or 3.5 mm panel mount is more reliable than a bare wire through a grommet.
  • Label all panel connectors clearly — Ethernet ports in particular can be confused if more than one is present (e.g., InTime vs secondary NIC vs VP).

Laser Bloop Light Extension

From a 2026-03-31 community question about extending the laser bloop light:

  • The laser bloop light cable is often short and must reach from the bloop light (on the camera) back to the operator case or trigger interface.
  • An extension cable using the correct connector type (check the specific bloop unit — usually a thin 3.5 mm or proprietary locking connector) can be built or ordered.
  • Keep the extension cable away from mains power cables to avoid interference on the trigger signal.

Cinebot Mini / Nano Arm Pelican Case

From a 2026-03-19 community thread on transporting the Cinebot Mini or Nano arm:

  • The arm fits into a Pelican 1650 or similar large case with custom foam.
  • Cut foam to support the arm in its folded/transport position — do not rely on the arm's locking pins alone to prevent movement in transit.
  • The hand controller and cables can share the same case if space allows; pad them separately.

Official Documentation

Flair Classic Manual — Ch.1 Introduction: Safety — p.15