SP-1 Project
4-Way 9V Power Distribution Unit
SP-1 designed and assembled a compact 4-way 9V power distribution unit, converting mains input into a stable DC supply for multiple devices inside an integrated system.
Client
Technology integrator requiring a compact internal power distribution solution for multi-device systems.
Objective
Design and assemble a reliable power distribution unit to convert mains power into a stable 9V DC supply for multiple connected devices. The unit needed to fit inside a compact metal enclosure, provide 4 DC outputs and follow a repeatable assembly process suitable for consistent production builds.
Challenge
Small power modules still require careful integration.
The system needed to combine mains input, AC-to-DC conversion, DC output distribution, cable retention and earth bonding inside a confined enclosure. The internal layout had to be safe, serviceable and repeatable, with clear routing for live, neutral, earth and low-voltage DC connections.
The unit needed to support:
- mains input through an IEC C14 inlet
- regulated 9V DC output
- 4-way device power distribution
- secure cable entry and strain relief
- correct chassis and PSU earth bonding
- insulated PSU mounting
- custom internal cable assemblies
- repeatable assembly and test process
- compact integration into wider electronic systems
Solution
SP-1 delivered a compact enclosed 4-way 9V power distribution unit.
The unit was built around a regulated XP Power 9V PSU, mounted inside a custom metal enclosure with an internal PSU insulator, spacers and defined fixing points. An IEC C14 mains inlet provided the AC input, with custom live and neutral wiring routed to the PSU input connector.
Earth bonding was integrated between the mains inlet, PSU ground tab and internal chassis earth stud, using dedicated cable assemblies, shakeproof washers and a locking nut arrangement.
The DC output from the PSU was connected to a custom 4-way splitter cable, allowing the unit to distribute 9V DC power to multiple devices from a single enclosed module. The assembly process was documented to support consistent builds, cable routing, strain relief and final testing.
Key features included:
- compact enclosed 9V DC power distribution unit
- IEC C14 mains input
- regulated XP Power 9V PSU
- 4-way DC splitter output
- custom metal enclosure
- PSU insulator and spacer mounting
- dedicated earth bonding to chassis
- custom live, neutral, earth and DC cable assemblies
- rubber grommet and cable tie strain relief
- defined assembly procedure
- serial number labelling and test process
Outcome
The finished unit provided a compact, repeatable power module for distributing 9V DC to multiple devices within an integrated system. By combining mains input, regulated DC conversion, earthing, cable routing and output distribution into 1 enclosed assembly, SP-1 reduced wiring complexity and created a cleaner module for system-level integration. The result was a reliable, production-ready power distribution unit that could be built consistently and installed as part of a wider electronic system.
Project highlights
Client: Technology integrator
Application: Internal power distribution for multi-device systems
System type: Compact 4-way 9V DC power distribution unit
Input: IEC C14 mains input
Output: 4-way 9V DC distribution
Core functions: AC-to-DC conversion, power distribution, earth bonding and cable management
Enclosure: Custom metal enclosure with insulated PSU mounting
SP-1 role: Power integration, enclosure design, cable assembly, grounding layout, assembly documentation and manufacture
