Composite Central Module for Pull-Resistant Locking Cylinders
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Solution Overview
Problem
Existing locking cylinders face challenges in achieving stability against core pulling and twisting while being manufactured in a simple and cost-effective manner, with methods like milling brass being complex and costly, and zinc die-casting lacking sufficient strength.
Innovation Solution
A central module for a modular locking cylinder is designed with a casting process using steel connecting elements and die-cast zinc parts, featuring support surfaces and recesses for high stability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the central module is milled from brass, then sufficient stability and strength are achieved, but manufacturing complexity and material costs increase significantly
Solution Approach 1:
The central module is divided into multiple separate components: a die-cast zinc central module element and steel connecting elements. This segmentation allows each component to be manufactured using optimized processes (die-casting for the main body, steel forming for connecting elements) rather than requiring complex milling of solid brass, thereby reducing manufacturing complexity while maintaining strength through the assembled structure.
Solution Approach 2:
The invention uses a composite construction combining die-cast zinc for the central module element and steel for the connecting elements. This composite approach leverages the advantages of each material (zinc for cost-effective die-casting, steel for high strength and ductility) to achieve the required stability without the complexity and cost of solid brass milling.
2Strength
If the central module is milled from brass, then sufficient stability is achieved, but material waste increases significantly
Solution Approach 1:
By segmenting the central module into a die-cast zinc element and separate steel connecting elements, the design enables more precise material usage. The die-cast process allows complex geometries to be formed directly from the zinc element without requiring substantial material removal, significantly reducing waste compared to milling solid brass.
Solution Approach 2:
The invention changes the manufacturing parameters from subtractive milling of brass to die-casting of zinc. This parameter change fundamentally alters the material utilization efficiency, allowing the central module element to be formed with minimal material loss while maintaining the required structural stability.
3Ease of manufacture
If the central module is made as a single die-cast part, then manufacturing simplicity is achieved, but stability against core pulling and twisting is insufficient
Solution Approach 1:
The central module is segmented into a die-cast zinc central module element and separate steel connecting elements. This segmentation allows the zinc element to be manufactured simply through die-casting while the steel connecting elements provide the necessary strength and stability against core pulling and twisting, compensating for the simpler manufacturing process.
Solution Approach 2:
The composite structure combines die-cast zinc (easy to manufacture) with steel connecting elements (high strength and ductility). This composite approach maintains manufacturing simplicity for the main body while using steel to provide the required resistance against core pulling and twisting forces.
4Ease of manufacture
If zinc die-cast is used for the central module, then manufacturing simplicity and cost-effectiveness are achieved, but stability against core pulling is insufficient
Solution Approach 1:
The central module is divided into a die-cast zinc element and separate steel connecting elements. This segmentation allows the zinc element to be manufactured simply and cost-effectively through die-casting, while the steel connecting elements provide the high strength and ductility needed to resist core pulling forces.
Solution Approach 2:
The invention uses a composite material system combining die-cast zinc for cost-effective manufacturing with steel connecting elements for high strength. The steel elements' ductility and tensile strength specifically address the core pulling resistance requirement while maintaining the manufacturing simplicity of the zinc component.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a central module for a modular double-sided locking cylinder. The central module is designed to be arranged along a rotation axis defined by the locking cylinder for a cylinder core between a first cylinder housing element and a second cylinder housing element of the locking cylinder. The central module comprises at least one central module element (2, 3) manufactured by a casting process and at least one connecting element (8, 9) made of steel. The at least one central module element (2, 3) has support surfaces for bearing against the cylinder housing elements. The at least one connecting element (8, 9) extends substantially parallel to the rotation axis between two end regions and is arranged with its end regions to engage in at least one recess (24, 34) of the at least one central module element (2, 3).