Control Box Locking System for Automotive HVAC Assembly
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Solution Overview
Problem
The assembly of automotive air conditioning system control boxes is challenging due to the need for precise angular alignment of control shafts, which is time-consuming and prone to errors, and the use of expensive special tools that are not retained for maintenance, complicating the assembly and maintenance processes.
Innovation Solution
The implementation of a control box design featuring inner and intermediate shafts immobilized by locking devices secured to the base and intermediate panel, with unlocking cams that automatically release the shafts during assembly, allowing for precise alignment and easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the operator uses a special assembly tool to prevent shaft rotation during assembly, then the assembly precision is improved, but the device complexity and cost increase
Solution Approach 1:
The control box assembly performs its own shaft immobilization function through integrated locking devices that are part of the standard assembly structure. The locking devices with latching indices automatically engage with the shafts to prevent rotation during assembly, eliminating the need for external special tools while maintaining assembly precision.
2Manufacturing precision
If the operator manually positions and monitors shaft rotation during assembly, then the assembly precision is improved, but the assembly time increases
Solution Approach 1:
The locking devices are pre-configured on the control box components before assembly begins. The latching indices are positioned to automatically engage with the shafts as they are inserted, preventing rotation from the outset without requiring manual monitoring or adjustment during the assembly process.
3Manufacturing precision
If the shafts are immobilized by locking devices during assembly, then the assembly precision is improved, but the shafts must be released after assembly
Solution Approach 1:
The locking devices transition from a locked state during assembly to an unlocked state during operation. The cam mechanisms are designed to automatically switch the latching indices from engaged to disengaged positions as the control box components are assembled together, providing dynamic adaptability without additional complexity.
4Manufacturing precision
If special factory tools are used for assembly, then the assembly precision is improved, but the maintenance complexity increases due to tool unavailability
Solution Approach 1:
The control box assembly structure serves multiple functions: it provides shaft immobilization during assembly, maintains precision alignment during operation, and allows easy disassembly for maintenance. The locking devices are integrated into the standard components, making them functional throughout the product lifecycle without requiring specialized tools for any operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures precise and efficient assembly of the control box components, reducing assembly time and costs by allowing for automatic release of shafts, facilitating maintenance without the need for special tools.
Implementation Method 1
each locking device comprises a latching index elastically urged by an elastic element towards the locked state
Data Source
Figure 1
Figure 2~3
Figure 4~9
AI summary
The box (10) has a base (12) and an intermediate panel (14) with respective linear and rotary locking devices (26, 28) that fix corresponding inner and intermediate shafts (18, 20) in determined angular positions, before and during assembling of the base and the panel, at respective locked states. The devices are switched into respective unlocked states. The base and the panel have respective unlocking cams (30, 32) cooperating with the corresponding devices, for switching the devices from the locked states to the unlocked states, during assembling of the base and the panel.