ELECTRICAL SYSTEM DESIGN
Expert electrical design services for automotive and off-grid applications, covering everything from system architecture to high-voltage DC and 230V AC systems.
We specialise in comprehensive electrical design solutions tailored for both automotive and off-grid applications. Our capabilities include complete component and system-level design, architecture and schematic development, cable and harness design, and control systems engineering. We seamlessly integrate third-party products and specialise in complex power systems. Whether it's a new build or integration into an existing platform, we deliver reliable, scalable, and standards-compliant designs.
Frequently Asked Questions
Switchgear costs vary depending on the type, rating, and quantity of components required. Merlin Power supplies individual switchgear components as well as complete engineered distribution and switchgear solutions as part of their electrical system design service. Contact the team or book an initial consultation to discuss your requirements and receive appropriate product recommendations and pricing.
Properly specified switchgear protects equipment and personnel by containing electrical faults before they cause damage or danger. In complex and critical vehicle and off-grid power systems,like those that can be designed by Merlin Power, quality switchgear ensures safe operation, ease of maintenance, and compliance with relevant electrical standards, critical for military, emergency service, and commercial fleet applications.
Switchgear provides manual or automatic means to energise, de-energise, and protect electrical circuits. Circuit breakers and fuses protect against overcurrent, while isolators allow safe maintenance. Merlin Power's electrical system design team specifies appropriate switchgear for each circuit based on the load, voltage, and fault current levels in the system architecture. See also their range of fuse blocks and distribution components.
Electrical switchgear refers to the combination of switches, circuit breakers, fuses, and isolators used to control, protect, and isolate electrical circuits within a power system. Merlin Power incorporates switchgear into the complete electrical system designs we produce for automotive, marine, and off-grid applications, ensuring every circuit is safely controlled and protected.
The cost of an electrical system design service depends on the complexity of the system and the level of documentation and validation required. Merlin Power offers design services for both new-build and retrofit projects, often alongside our bespoke installation and system integration services. Contact the team or book a 10-minute initial consultation to discuss your requirements and receive a project-specific quotation.
Merlin Power's electrical system design service delivers reliable, scalable, and standards-compliant designs backed by 35+ years of experience. Our ISO 14001 and ISO 9001-accredited process ensures consistent quality, and every design is documented thoroughly for ease of maintenance and future modification. Customers range from individual vehicle builders to government contractors. Explore Merlin’s rapid prototyping service to validate designs before committing to full production.
Merlin Power's electrical system design process begins with defining the application requirements, available power sources, and load demands. The team then develops a complete system architecture, produces detailed schematics, specifies all components, and designs the cabling and harness layout. Third-party product integration is handled seamlessly, and all designs are validated for compliance.
Electrical system design involves creating the complete technical blueprint for a vehicle's or installation's electrical infrastructure, from the overall system architecture and schematic development through to cable and harness design, control systems engineering, and component selection. Merlin Power specialises in comprehensive electrical design for automotive and off-grid power applications.
A power distribution system manages the routing of DC and AC electrical power from sources such as batteries, and shore power to circuits and loads within your vehicle, vessels, or off-grid application. Merlin Power specialises in the design and supply of power distribution systems that integrate switches, fuse blocks, circuit breakers, busbars, connectors, and power posts, all engineered for safety, reliability, and ease of install and maintenance.
Costs vary depending on the complexity of the system, the number of circuits, the components specified, and whether design and installation services are required. Merlin Power can supply everything from individual fuse blocks and distribution components to fully engineered and integrated systems. A well designed system eliminates unnecessary future repair costs, meaning an initial investment will save you money later down the line. Contact the team to discuss your project and receive a tailored solution and quotation, or explore their electrical system design service for a complete turnkey approach.
A properly designed distribution system primarily ensures safety of your electrical system, both protecting the user and the equipment itself. This inherently means that every load receives the right voltage and current, that any potential faults are contained, and that the system can be safely operated, maintained and modified. Merlin Power's ISO 9001-accredited design process delivers standards-compliant, scalable distribution solutions trusted by military, emergency service, and commercial fleet operators.
Power flows from the source through a distribution board or busbar, protected by correctly rated fuses or circuit breakers, and then on to individual circuits and loads. Merlin Power's electrical system design team develops bespoke distribution architectures for automotive and off-grid applications, covering DC and 230V AC systems, with full schematic documentation and compliance validation.
Electrical manufacturing at Merlin Power involves the design, production, and assembly of electrical systems, wiring harnesses, control panels, and power management units. Based in Exeter with over 35 years of experience, Merlin Power manufactures products and systems for some of the world's most demanding applications, including military land platforms, emergency service vehicles, and luxury yachts. See their full electrical system design capability for details
Merlin Power's electrical manufacturing process encompasses system architecture, schematic development, component sourcing, cable and harness design, and final assembly. The team holds ISO 9001 and ISO 14001 certifications, ensuring consistent quality and environmental responsibility throughout. Every manufactured system is functionally tested and validated before delivery. For mechanical enclosure work alongside electrical assembly, explore their rapid prototyping service, a process designed to support urgent operational requirements.
Costs depend on the complexity, volume, and specifications of the required system or assembly. Merlin Power works with clients at all scales, from single bespoke units to fleets of 500+ vehicles. Related services such as system integration and bespoke installation are also available. Contact the team to discuss your project scope and receive a tailored quotation.