Relaiskasten-Montage

Aircraft Relay Panel Assembly

A client in the aerospace industry, aiming to establish themselves as a leading manufacturer of amphibious aircraft, sought to enhance the reliability and efficiency of their Relay Panel Assembly. They approached us to address their wiring harness issues and optimize the assembly for improved performance.

Scope

The project involved the comprehensive redesign and optimisation of the Relay Panel Assembly, with a focus on creating a more compact, lightweight, and efficient solution.

The scope included:

Needs Assessment: Collaborating closely with the client to understand their unique requirements and constraints, ensuring that the new relay panel would meet their specific needs. Design Innovation: Utilising cutting-edge aerospace technology to conceptualise a new, streamlined design incorporating lightweight materials and efficient wiring solutions. Prototyping and Testing: Developing prototypes of the new design and conducting rigorous testing to ensure compliance with safety and performance standards. Manufacturing Optimisation: Simplifying the design to ease production complexity, thereby improving manufacturing efficiency and reducing production time.

Challenge

The primary challenge was to create a relay panel that was not only more compact and lightweight but also maintained high reliability and performance standards. This required innovative design solutions that could meet the stringent demands of the aerospace industry while also being cost-effective.

Solution

Our approach to addressing the challenge involved:

Collaborative Design Process: We worked closely with the client to gain a deep understanding of their needs and constraints, leading to a comprehensive assessment of the existing Relay Panel Assembly.

Innovative Design: Leveraging advanced technology, we designed a new relay panel that was more compact, lightweight, and efficient. The new design incorporated streamlined wiring and lightweight materials, enhancing both performance and reliability.

Manufacturing Efficiency: The design was optimised for manufacturing, simplifying the production process and reducing assembly time and complexity.

Value and Benefits

The project delivered significant value through the following outcomes:

The new relay panel design maintained the highest safety and performance standards, ensuring the reliability of the aircraft's electrical systems.

The streamlined design and manufacturing optimisations led to reduced production costs, enhancing profitability for the client.

The simplified installation process and reduced space requirements contributed to more efficient operations, saving time and reducing complexity during assembly.

Through a collaborative and innovative approach, we were able to help the client achieve their goal of enhancing the reliability and efficiency of their Relay Panel Assembly, positioning them for success in the competitive aerospace industry.