Physically reconfigurable interactive control system

A reconfigurable control system (10) enabling a designer to layout, configure and test control panel designs includes an enclosure base (12), a matrix panel (14) and a plurality of modules (34) which are adapted to receive at least one control panel element. The base (44) of each module (34) has a plurality of holes (46) which align with corresponding apertures (22) provided in the matrix panel (14). A fastener (24) is passed through the aligning apertures (22, 46) of the matrix panel (14) and module (34), respectively, to provide removable mounting.

BACKGROUND OF THE INVENTION 
1. Technical Field 
The present invention relates to a system for designing a control panel 
and, more particularly, to a reconfigurable control system which 
facilitates the layout, configuration, and testing of control panels. 
2. Discussion 
Control panel layouts are currently designed by several methods. The most 
common method of designing control panels is through layout of a design 
which is drawn on paper with drafting tools or by computer aided design. 
In such a method, the two-dimensional designs developed on paper or 
computer can be incorporated into a prototype. One problem with this 
method is that it does not promote refinement or experimentation with a 
physical design layout due to prohibitive costs for the redesigning and 
building of prototypes. 
With the advent of computer graphics, control panels may alternatively be 
designed to incorporate interactive computer displays. This interaction 
with the computer simulated control panel is made possible through the 
application of interactive devices such as touch sensitive panels 
overlaying the computer screen or other external pointing devices. This 
particular design method enables one to quickly reconfigure a simulated 
panel through the reprogramming of the display, at a relatively modest 
cost. However, such a technique is not without its own drawbacks. For 
example, computer graphics with interactive computer displays offer 
extremely low physical fidelity for interactions with a simulated control 
panel. 
Accordingly, it is a primary objective of the present invention to combine 
the flexibility and cost effectiveness of a computer assisted simulation 
control panel with the high physical fidelity of a prototype. 
Another object of the present invention is to provide an inexpensive means 
to design and experiment with control panel layouts in a high-fidelity 
environment. 
A further object of the present invention is to provide a reconfigurable 
system for control panel design and testing in which control panel 
elements can be moved quickly and easily, either independently or within 
small groupings of elements. 
SUMMARY OF THE INVENTION 
In accordance with the teachings of the present invention there is provided 
a physically reconfigurable interactive control system (PHRICS) for 
designing and testing a control panel layout. The system includes an 
enclosure base, a matrix panel mountable to the base having a plurality of 
apertures, at least one module and means for mounting the module on the 
matrix panel. The module includes a base having a plurality of apertures 
and a top adapted to receive at least one control panel element. At least 
one aperture formed in the base of the module will align and mate with at 
least one aperture located in the matrix panel. A fastener is projectable 
through the mating apertures to enable removable mounting. 
The present invention provides a system in which control panel elements 
including switches, indicators, gages, and other interface components can 
be mounted into modules which are positioned on a matrix panel, which 
thereby allows discrete changes in position and orientation. The modules 
are releasably fastened to the matrix panel by quick release fasteners to 
improve physical reconfigurability. Control panel elements may be easily 
and quickly interchanged between modules. The functions of the interface 
components are defined and controlled by software.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
As generally shown in FIGS. 1 through 3, the reconfigurable system 10 for 
designing a control panel includes an enclosure base 12 and a matrix panel 
14. In the preferred embodiment, the enclosure base 12 is a rectangular, 
deep drawn aluminum can, having a back 16 and four sides 18. Apertures 20 
are provided in the sides 18 of the base 12 so that the base 12 may be 
attached to another substantially similar base, in order to enlarge the 
working area (see, modules systems 10b and 10c in FIG. 6). The depth of 
the sides 18 of the base 12 in the preferred embodiment is three inches. 
Cut-outs 21 and 23 are provided in both the back 16 of the base 12 and the 
matrix panel 14 to accommodate the mounting of an electrical connector, 
which is typically a DB-25 connector for connection to signal conditioning 
circuitry and a computer interface. This interface, which is illustrated 
in FIG. 6 will be described in further detail below. 
The matrix panel 14 of the present invention is cut from 1/8 inch aluminum 
sheets and sized to fit loosely within the enclosure base 12. This sizing 
enhances ease of interchangability. In the preferred embodiment, the 
matrix panel 14 is perforated with an array of 0.440" diameter apertures 
22, 1" on center. The apertures 22 are sized to accommodate fractional 
turn fasteners 24, which will be discussed in further detail below. An 
electrical wiring harness 29 can be mounted to the rear of the matrix 
panel 14. 
The matrix panel 14 is installed in the enclosure base 12 using four 1 inch 
spacers 28, each adapted to receive an 8-32 screw 30, to fasten the matrix 
panel 14 to the enclosure base back 16. The screws 30 pass through 
attachment holes 31 in the matrix panel 14, and into the spacers 28. The 
spacers 28 create a cavity 32 defined by the base sides 18, base back 16 
and the matrix panel 14. The cavity 32 is of sufficient depth to 
accommodate the fractional turn fasteners 24 and wiring harness 29. 
The system 10 of the present invention is designed to allow control panel 
elements to be mounted either individually or in small groupings into 
modules 34 which can be quickly added to, removed from, or repositioned 
within a control panel design layout. The particular control panel 
elements depicted within the various drawings include a lamp 36, a toggle 
switch 38, a four position switch 40 and a split legend, or square, switch 
42. Envisioned, but not illustrated, is the reconfigurable mounting of 
other control panel elements including but not limited to meters, key 
pads, and analog devices. 
In order to maximize reconfigurability as far as type and location within a 
certain physical area, the control panel elements are mounted into the 
modules 34. The modules 34 of the present invention are preferably 
unitarily formed from a continuous length of aluminum. The modules 34 have 
a flange or bottom 44 with a plurality of mounting holes 46 drilled at 0.5 
inch increments, thereby allowing for a physical reconfiguration of each 
module 34 at 0.5 inch intervals. 
In use, at least one of the mounting holes 46 drilled in the base 44 of the 
module 34 are aligned with at least one of the apertures 22 disposed in 
the matrix panel 14. Preferably, two holes 46 in the bottom of the module 
34 will align with corresponding apertures 22 in the matrix panel 14, 
thereby prohibiting the module 34 from rotating. After such alignment is 
accomplished, a fastener 24 is passed through the aligned apertures 22, 
46, thereby serving to removably mount the module 34 to the matrix panel 
14. 
A particular module 34 can accommodate any number of various control panel 
elements. Referring to FIG. 1, illustrated is a module 34a having a top 
48a with a round cut-out 50. Such a round cut-out 50 accommodates a wide 
variety of toggle switches, round push buttons, and indicator lamps. In 
the preferred embodiment, the modules 34 are box shaped, and have a 
standard 2 inch depth. 
Further referring to FIG. 1, shown is a module 34b having two rectangular 
cut-outs 52. The cut-outs 52 are adapted to accommodate control panel 
elements such as the illustrated split legend push button switch 42 in one 
cut-out 52, and a similar element in the other cut-out 52. By having 
multiple portions on a single module 34 adapted to receive control panel 
elements, ease of reconfigurability is enhanced insofar as control panel 
elements can be moved in small clusters. 
Referring now to FIG. 4, illustrated is another embodiment of a module 34c 
for use in the present system 10. In this embodiment, the module 34c is 
formed such that the base 44c is disposed directly below the top 48c. The 
top 48c of this module 34c further is provided with a plurality of access 
holes 54 to access the heads of the fasteners 24 protruding through holes 
46c in base 44c. The access holes 54 should be sufficiently large enough 
to accommodate a screwdriver. This particular embodiment of the module 34c 
decreases its footprint thereby maximizing reconfigurability and space 
efficiency. 
The preferred fastener 24 of the system 10 is a captive device such as 
Southco brand fractional turn fastener which contains a neoprene sleeve 
(not shown) on its end. Turning the fastener head one-quarter turn 
activates a cam which compresses the neoprene sleeve within the mounting 
hole 22, securing the module 34. The fastener 24 has an audible click 
which reports when the cam becomes fully engaged. Reversing the screw 
direction releases the fastener 34. 
Further in the preferred embodiment, a bezel 62 is provided. After a 
control panel configuration has been developed, a bezel 62 with cut-outs 
69 therein is constructed from materials such as 0.125" ABS plastic, foam 
core or cardboard can be fabricated to cover the assembly. Control panel 
element names or positions can then be added by way of silk screening or 
dry transfer letters in order to facilitate element identification. A 
slight overlap of the bezel 62 beyond the sides 18 of the base enclosure 
12 is preferred. Each side 18 of the enclosure base 12 has a lip 64. The 
bezel 62 is attached to the lip 64 with 4-40 bezel screws 63 passing 
through holes 65 and 67 in lip 64 and bezel 62, respectively. 
Turning attention to FIG. 6, illustrated is the preferred embodiment of the 
electrical interface 56 for the present system. The electrical interface 
56 includes signal conditional circuitry 58 and an interface control 
computer 60. The interface control computer 60 includes discrete input and 
output modules, analog input and output modules, and interface control 
software. 
In the preferred embodiment, as shown in FIG. 6, computer simulation is 
accomplished in a separate computer. In an alternative embodiment, a 
single computer is provided which has the appropriate hardware and 
software devices, and sufficient processing capabilities to run both the 
simulator software and the interface control software. 
The system 10 of the present invention is a natural step in the development 
of products to aid in the design and development of user interface 
equipment. This technology should be applicable to the design of control 
panels for military applications as well as commercial applications, such 
as the design of dashboards in automobiles and the design of controls in 
the nuclear industry. This product may also find application in any 
industry which designs control layouts and/or studies the effects of 
layouts on operation by humans. 
The present invention provides flexible and inexpensive means to design and 
experiment with the layout of control panel elements in a high-fidelity 
environment. 
Although this invention has been described in detail with reference to 
certain preferred embodiments and specific examples, variations and 
modifications exist within the scope and spirit of the invention as 
described and defined in the claims. For example, it is envisioned that 
the modules 34 of the system 10 could be redesigned to accommodate less 
traditional control panel elements. This alternative construction should 
fall within the spirit of the invention. 
While the above description constitutes the preferred embodiment of the 
invention, it will be appreciated that the invention is susceptible to 
modification, variation, and change without departing from the proper 
scope or fair meaning of the accompanying claims.