Relay Box Automation for Test System Scalability
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Solution Overview
Problem
Current automated test systems for electrically controlled items are cumbersome, costly, and not scalable, as they require manual cable switching and custom patch panels, leading to high labor costs, errors, and wear on equipment, making it inefficient to switch between multiple electrical components during testing.
Innovation Solution
A large scale automated test system using relay boxes with multiple relay boards and computer-controlled bank switching apparatus that quickly and efficiently switches between electrical components and a test version of an aircraft, reducing switch time and power consumption, and allowing for easy scalability by adding or removing relay boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual cable switching is used to communicate different electrical components with the test system, then the system can be configured flexibly, but the switching time increases significantly and labor costs rise
Solution Approach 1:
A relay box is introduced as an intermediary device between the electrical components and the test system. The relay box contains multiple relay cards that can be selectively activated to connect different electrical components to the test system through a single persistent cable connection, eliminating the need for manual cable disconnection and reconnection while maintaining configuration flexibility
Solution Approach 2:
The relay box creates virtual cable connections through relay switches that simulate the effect of physical cable connections. Each relay card contains multiple relays that can be electronically controlled to establish or break connections, effectively copying the functionality of physical cable switching without the associated time loss and wear
2Adaptability or versatility
If manual cable switching is used to connect different electrical components, then the system can accommodate various components, but wear on connectors increases and equipment life decreases
Solution Approach 1:
The relay box serves as a protective intermediary that handles all switching operations internally through relay contacts. The external connectors remain stationary and are never disconnected, while the relay cards inside the relay box handle the switching wear through their own internal contacts, thereby protecting the main system connectors from wear
Solution Approach 2:
The relay cards are designed as replaceable, lower-cost components that can be easily swapped if worn. This allows the expensive main system connectors to be protected while using cheaper relay cards that can be replaced if needed, effectively sacrificing a less critical component to protect critical ones
3Ease of operation
If custom patch panels are constructed for each electrical component, then switching between components becomes easier, but the hardware costs and engineering time increase significantly
Solution Approach 1:
A single relay box is designed to handle multiple electrical components through multiple relay cards. Each relay card can be configured to connect different components, making the relay box a universal switching device that replaces the need for multiple custom patch panels. The relay box provides a standardized interface that can accommodate various components without requiring custom hardware for each
4Extent of automation
If VME bus based cabinet is used to switch between electrical components, then automated switching is achieved, but the power consumption increases due to active control of hundreds of signals
Solution Approach 1:
The switching function is segmented into multiple independent relay cards, each handling a subset of signals. Each relay card can be controlled independently and only consumes power when switching is required. This segmentation allows automated switching while reducing overall power consumption compared to a monolithic active switching system that must continuously monitor and control all signals
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 rapid switching between electrical components with minimal upfront costs and low power consumption, increasing the number of components that can be tested without the need for manual cable switching or custom patch panels, thus improving efficiency and extending equipment life.
Implementation Method 1
A relay board is provided in a relay box. The relay board comprises a plurality of relay switches communicated with the printed circuit.
Data Source
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AI summary
A large scale automated test system employs one or more relay boxes that contain and support one or more relay boards. Each relay board is operated to selectively communicate an item being designed, for example a cell phone, an automobile, or an aircraft, with two or more electrical components being considered in the design of the item to evaluate the performance of each electrical component in the item being designed.