How to design a PLC control panel?

There are too many variables to analyze, so you would have to put more detailed information, as for example, location of the panel, number of I/O cabinets, quantity and type of PLC and quantity of modules, type of MCC, type and quantity of cubicles, same for the drives, if they are soft starters they may occupy more space, type of mountings for the electrical and PLC components, etc.. Once all the information is available you can go to a manufacturer of panels and they can develop it. Though nowadays you can ask the MCC vendor to supply the equipment with either space in it for mounting the PLC hardware or even install them and send the fully assembled pieces.

To start, you will need to do the following:
1. The disconnect for the panel goes on the right side.
2. The control, safety relays, and motor starters go in the top row.
3. Your PLC and supporting I/O goes in the second row.
4. You need to add wiring ducts in between for your control wires.
5. You motor controls and drives go in the very bottom of the panel.
6. You need to make sure that the control wiring and Power cables are in separate ducts.
7. The low power signal wires must be separated to avoid signal interference
8. Use shielded cable for low power signals.
9. Make sure there is enough ventilation, add some panel fans if needed or air conditioner, to avoid over heating of the components inside the panel.