HMI Solution on a Tight Timeline for a Military Aircraft
Challenge
An existing military/defense customer that Epec had worked with in the past on other product solutions we offer submitted an RFQ request for an HMI through our website.
This request was followed up by the Epec Regional Business Development Manager. Once the initial contact was made, we realized this was something Epec could support. Our Epec Regional Business Development Manager scheduled a call with Epec’s Product Manager, along with our team of electrical and mechanical engineers so we could all meet the customer’s engineering team. Our goal was to learn more about the project so we could all get a better understanding of the requirements and potential challenges.
This HMI bezel requirement was for a defense program of record that was under an extremely tight timeline. The customer did not have the engineering capabilities or the expertise to develop this user interface that controls hardware to be used within the cockpit of an aircraft. The customer came to Epec to see if we could help develop a solution to meet their timeline, and then what that would cost.
For this particular project, the total cost was not a driving factor. The most critical requirement was their timeline. The customer had a strict deadline to participate in a flight test, and if they did not have hardware ready, they would miss the flight test and lose out on their chance to participate in this demonstration. Because the customer knew what type of device they wanted, and all they needed was a manufacturer to help develop the solution and build, Epec was able to help and was awarded a contract to support this bezel project.
Solution
Epec developed a custom HMI bezel and the associated control board with a keypad. This design was built with a series of tactile buttons known as dome switches and NVIS Green B-compliant LEDS. This included the development of several custom PCBs with over two dozen surface-mounted components and 20 discrete LEDs. Epec was able to develop this bezel, with a PCBA, and the entire control portion of this unit within the timeline and cost requirements of our customer.
Most importantly, Epec was given design flexibility to modify the footprint of the bezel and the total number of buttons. By modifying the form factor of the bezel, Epec could reduce the number of unique keypads required and develop a modular approach so that one 5 x button keypad could be used along all four edges of the bezel. This reduced the complexity of the build and helped offset some challenging minimum order quantity issues.
Since the customer was in such a timeline crunch, they were willing to reduce the requirements of the project to meet their timeline. The customer allowed Epec to use off-the-shelf components like switches and LEDs, this helped reduce the timeline and get a prototype built in a few weeks. But still, we quickly found not everything was available and in stock. Epec engaged our NVIS material partner and was able to secure a small number of samples to address our final shortage and complete the project.
Result
The result was a functioning prototype avionics bezel that complied with our customers’ primary objectives. Epec built and shipped our bezel on schedule which allowed this customer to participate in their flight test.
Our value add was that Epec offered a one-stop-shop solution that was able to develop the design, create the necessary manufacturing data and Gerber files, produce the part, assemble it, and troubleshoot issues helping our customer debug the integration.
Working with the customer early and having several in-depth design reviews with their engineering team allowed Epec to review various critical design challenges and a solution for a way out of this logjam. In doing so, Epec helped this customer to get their project off the ground.
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