Cockpit Pushbutton Relay Assembly for Legacy Switch Automation
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Solution Overview
Problem
Legacy aircraft cockpits require invasive modifications and extensive analysis to automate electromechanical pushbutton switches, making conversion to autonomous features costly and cumbersome, and existing automation methods introduce new failure modes.
Innovation Solution
An electro-mechanical assembly comprising a momentary pushbutton switch, a bi-stable relay, and a toggle component that allows both manual and automatic actuation of aircraft systems, maintaining state even in power loss without introducing new failure modes, using a combination of user input and command signals from a mission processor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional fly-by-wire automation methods are used to automate aircraft pushbutton switches, then automation capability is improved, but device complexity and system invasiveness increase significantly
Solution Approach 1:
A relay component is introduced as an intermediary device between the existing pushbutton switch and the aircraft system. The relay receives commands from either the pushbutton or the processor and automatically manages switch states, providing automation capability while interfacing with legacy systems through standard electrical connections without requiring invasive modifications to aircraft subsystem schematics
Solution Approach 2:
The relay component serves multiple functions: it acts as a manual switch when activated by the pushbutton, responds to automated processor commands, provides visual feedback through illumination, and maintains system state during power interruptions. This multi-functionality consolidates what would otherwise require separate systems into a single universal component
2Extent of automation
If existing automation methods are implemented in legacy cockpits, then autonomous features are enabled, but conversion cost and manufacturing complexity increase due to invasive modifications
Solution Approach 1:
The automation functionality is extracted from the existing pushbutton switch and implemented separately through the relay component. This allows the automation logic to be implemented independently without modifying the original switch or aircraft subsystems, enabling retrofitting of legacy cockpits through simple electrical connections rather than invasive modifications
Solution Approach 2:
The relay component creates an electrical equivalent or copy of the pushbutton switch's functionality, allowing the system to respond to both manual pushbutton activation and automated processor commands in the same manner. This copying approach enables legacy systems to be automated without physically altering the original control interface
3Ease of operation
If automated switch control is implemented, then workload reduction is achieved, but new failure modes are introduced into the aircraft system
Solution Approach 1:
The relay component autonomously manages its own state transitions based on input commands from either the pushbutton or processor, eliminating the need for complex control logic in the aircraft's existing systems. The relay self-manages switching, latching, and feedback functions, reducing the computational burden on the processor and minimizing potential failure modes associated with software-controlled switching
4Stability of the object's composition
If bi-stable relay with toggle component is used, then state maintenance during power loss is achieved, but device complexity increases
Solution Approach 1:
The toggle component uses periodic or pulsed electrical signals to transition the bi-stable relay between its two stable states. Rather than requiring continuous power or complex control logic, the system uses momentary pulsed commands from the pushbutton or processor to trigger state changes, with the relay maintaining its state indefinitely without further input until the next pulse is received
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables cost-effective and non-invasive automation of aircraft switches, maintaining system integrity and preventing new failure modes, allowing for seamless integration of autonomous features into legacy cockpits without significant panel modifications.
Implementation Method 1
a bi-stable relay controlled by input commands from the pushbutton switch and input commands from the processor... The bi-stable relay is configured to control operation of one or more systems of an aircraft and maintain the state
Data Source
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AI summary
A cockpit switch device can include a pushbutton switch, a bi-stable relay and a toggle component. The pushbutton switch can be configured to be manually actuated by a user into a command state. The bi-stable relay can be controlled by input commands from the pushbutton switch and input commands from a processor, and can be configured to control operation of one or more systems of an a aircraft. The toggle component can be connected to the pushbutton switch, the processor and the bi-stable relay. The toggle component can receive an input command signal from at least one of the pushbutton switch or the processor, and cause a state of the bi-stable relay to be flipped responsive to the input command signal from the at least one of the pushbutton switch or the processor.