Open Relay Panel for Rotorcraft Add-In Kit Installation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The installation of add-in kits in rotorcrafts is cumbersome due to the need for new wiring and breaking open sealed panels, which complicates the process and increases workload.
Innovation Solution
An open relay panel with accessible terminals and pre-wired modules allows add-in kits to be installed by routing their wiring harness to the panel, eliminating the need for new wiring and minimizing disassembly of existing harnesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealed panels are used in rotorcraft, then protection and integrity are improved, but installation of add-in kits becomes cumbersome requiring breaking open panels and new wiring
Solution Approach 1:
The relay panel is segmented into a sealed portion and an open portion, allowing the panel to maintain overall integrity while providing accessible areas for installation work. The open portion contains exposed terminals and bussing modules that can be accessed without breaking the sealed enclosure.
Solution Approach 2:
The open relay panel acts as an intermediary device between the sealed environmental enclosure and the add-in kit wiring. By providing an intermediate access point with exposed terminals, it eliminates the need to break the sealed panel while still allowing electrical connections to be made.
2Reliability
If new wiring is required for add-in kits, then electrical connections are ensured, but installation time and complexity increase
Solution Approach 1:
The relay panel is pre-wired during manufacturing with terminals and bussing modules already connected to the aircraft's electrical system. This preliminary action eliminates the need for installers to perform time-consuming wiring tasks, as they only need to connect add-in kit harnesses to the pre-prepared terminals.
Solution Approach 2:
The relay panel provides self-service functionality by having all necessary electrical connections and terminals already in place. The panel serves itself by providing ready-to-connect terminals that automatically establish electrical connections when add-in kit harnesses are plugged in, without requiring additional wiring work.
3Reliability
If complex installation procedures are required, then proper installation is ensured, but qualification requirements increase
Solution Approach 1:
The complex wiring and connection tasks are extracted from the installation process and moved to the manufacturing phase. The relay panel comes pre-configured with all necessary electrical connections, terminals, and bussing modules, extracting the complexity from the field installation and leaving only simple harness connections for the installer.
Solution Approach 2:
The installation process is transformed from a complex multi-step procedure to a simple plug-and-play operation. By changing the state of the relay panel to have exposed terminals and pre-made connections, the installation complexity parameter is reduced while maintaining installation quality through standardized connectors.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
An open relay device and system (301) includes a chassis (303) having one or more openings (327); external connectors (309) on a first wall of the chassis (303), the external connectors (309) having a plurality of external connection terminals; ground bussing modules (311) attached to a second wall of the chassis (303); junction bussing modules (313) attached to a third wall of the chassis (303); relay sockets (315) attached to a fourth wall of the chassis (303); and wiring (317, 319, 321) electrically connecting the external connectors (309) to the ground bussing modules (311), the junction bussing modules (313), and the relay sockets (315), the wiring (317, 319, 321) further electrically connecting the relay sockets (315) to the junction bussing modules (313) and the ground bussing modules (311).