Advice needed for controller box layout

[JAZZCNC]

Really that case is little on the small side. You also need to think about heat and removing it with some fans.

Regards layout then first I wouldn't worry about trying to fit it all within in the confines of the plate because the reality is after it's wired you won't ever lift it out.

So I would put 2 drives up one side with one across top. The PSU like you have on it's side on the other side.
Then have the BOB Lower down because most of your wires connections will be coming in thru the bottom ie: Limits, E-stop, probes, etc
All Power and higher voltage wires or devices need to be kept far away from signal wires as possible and idealy run thru separate trunking crossing at a minimum. (See pic to get the idea of layout I mean)

You will need fuses for each drive and the main Psu. Regards Safety Relay then while you don't exactly need a Proper Safety relay with protected and monitored contacts you do need a Hardware driven safety system, which is what Clive S is refering too.

Relying just on Software E-stop is dangerous and shoudn't be used even on DIY router. Don't for one minute think this machine won't snap your arm like a carrot if get in the way, equaly neither will it think twice about ploughing it's cutter thru your hand just like it would a piece of Oak.!!

For this reason you need an E-stop safety system that uses a Relay to kill power to every thing that can hurt you. Then only after it's safe will it allow the system to Reset and Only with a Dedicated Momentery Reset button not just by releasing the E-stop button.

The extra cost is minimal so it's stupid to not do it.

[Bustercnc]

Relying just on Software E-stop is dangerous and shoudn't be used even on DIY router. Don't for one minute think this machine won't snap your arm like a carrot if get in the way, equaly neither will it think twice about ploughing it's cutter thru your hand just like it would a piece of Oak.!!

Jazzcnc comment stuck with me and I felt kinda insulted by it.
Afterwards I spent many hours reading forums and manufacturer specs in fear of duplicating many of the stupid/repeat questions already asked, it dawned on me, what kind of person is going to stick their hand infront of a drill bit when something goes wrong? instink dictates that you would pull the plug in the event of the estop failing.

No matter how many safety features are employed, the above will still happen unless a trip switch is fitted on a enclosure door, NOT mentioned in all that I have read so far

[JAZZCNC]

Jazzcnc comment stuck with me and I felt kinda insulted by it.
Afterwards I spent many hours reading forums and manufacturer specs in fear of duplicating many of the stupid/repeat questions already asked, it dawned on me, what kind of person is going to stick their hand infront of a drill bit when something goes wrong? instink dictates that you would pull the plug in the event of the estop failing.

No matter how many safety features are employed, the above will still happen unless a trip switch is fitted on a enclosure door, NOT mentioned in all that I have read so far

Well please don't be insulted that wasn't my intention. At same time I won't appologise for what I said because it's true and does happen.
No one would intentionaly stick there fingers in front of something capable of chopping them off but yet these things still happen.? Why!!

Because there brains don't engage quick enough and the desire to save there expensive cutting tool overides all rational thinking and before you know it there little piggy's are in there.!! They didn't think about the fact the spindle might grab there baggy Jumper and start pulling them into the machine.!!!

This is what goes thru there brain at that moment it grabs them.!!

" Oh shite can I reach the E-stop!! . . . .YES. . . . . Argh Hey . . . why's it not working???? . . . Oh because I'm a Stupid idiot and couldn't wait and do it right or too tight to buy a £3 Relay. . . .Can I reach the Plug or Cabinet door.? . . . NO. . . !!!!!!!!." At this point the pass out when there finger drops off.!

Sounds a little Dramatic hey.! But the missing part of my little finger can re-assure it's not and thoughts exactly like that will rush thru peoples brains when it happens.!

Safe E-top system isn't limited to one E-stop and there should be several depending on machine. In any case the E-stop should always be with-in reach of the user while at the machine or on the machine.

Again don't be offended just be sensible and do it right.!

No matter how many safety features are employed, the above will still happen unless a trip switch is fitted on a enclosure door, NOT mentioned in all that I have read so far

Look at my Pic and you'll see wires etc coming out back of door. These ON/OFF, Reset and E-stop. I also fit E-stops on the machine it's self, sometimes 2 or 3 on the machine depending on size. If really large long machine the Rope e-stop would be used.

[Clive S]

Jazzcnc comment stuck with me and I felt kinda insulted by it.

I think it is good that the comments have stuck and made you think but I don't feel you should be insulted.
It is true that software estops are just not good enough to be safe and the hardwire estop is designed to kill the power to the drives etc at the push of a button and not to restart unless a further button is pressed when everything is safe. A bit like a no volt release switch on a saw in that if it has been unplugged and then plugged it in again it won't start unless you again want it to by pressing the on button.