Acoustic Controller Housing Structure With Integrated Rack Flanges
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Solution Overview
Problem
Conventional acoustic controller housings are cumbersome to switch between tabletop and rack-mounted states due to separate mounting members, require many components, and have limited shape design freedom and risk deformation when made of resin.
Innovation Solution
A housing structure with a lightweight, resin-formed lower case and a metal upper unit, featuring integrated flanges for mounting and enhanced shape design freedom, which also function as rack mounting portions, reducing the number of components and simplifying the mounting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the housing is made of metal, then the strength and rigidity are improved, but the weight increases and shape design freedom is limited
Solution Approach 1:
The housing combines resin material for the lower case to achieve lightweight construction with metal material for the upper unit to maintain strength and rigidity. This composite material approach allows each part to be optimized for its specific functional requirements, resolving the contradiction between weight reduction and strength maintenance.
2Weight of moving object
If the housing is die-molded from synthetic resin to make it lightweight, then the weight is reduced and shape design freedom is increased, but the side walls may be deformed due to shrinkage
Solution Approach 1:
The lower case incorporates localized reinforced structures at critical positions to prevent deformation during molding. These local reinforcements compensate for shrinkage effects in specific areas without requiring complete redesign of the entire housing structure, maintaining both lightweight characteristics and manufacturing precision.
3Adaptability or versatility
If separate mounting members are used for rack installation, then the adaptability is improved, but the device complexity and number of components increase
Solution Approach 1:
The mounting members are integrated directly into the lower case as built-in features rather than being separate components. This merging of mounting functionality into the existing housing structure eliminates the need for additional separate mounting members, reducing overall component count while maintaining rack mounting adaptability.
Solution Approach 2:
The lower case is designed to serve multiple functions: it provides structural support for tabletop use and simultaneously incorporates mounting features for rack installation. This multi-functionality allows the same component to handle both stationary and rack-mounted configurations without requiring separate dedicated mounting members.
4Adaptability or versatility
If separate mounting members are used, then the adaptability is improved, but the ease of operation deteriorates due to cumbersome reattachment operations
Solution Approach 1:
The mounting members are pre-integrated into the lower case during manufacturing, so they are already in position and ready for use. This preliminary integration eliminates the need for field reattachment operations, making the switching between tabletop and rack-mounted states a simple matter of connecting the upper unit rather than reassembling multiple separate components.
Data Source
AI summary
A housing structure of an acoustic controller having a lower case which is lightweight, high in the degree of freedom in shape design, and capable of suppressing a deformation of side walls thereof after being molded. The lower case is integrally formed from resin into a rectangular dish shape having front, rear, left, right, and bottom plates. An upper unit is attached to an open upper part of the lower case. The left and right plates of the lower case have upper parts thereof formed into brim portions protruding outward in the left-to-right direction. Front and rear parts of each brim portion are further protruded outward and formed into flanges that function as mounting portions used for mounting the acoustic controller to a rack.