Deformable Fixing Wedge for Tool-Free Electrical Cabinet Assembly
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Solution Overview
Problem
Existing methods for mounting accessories in electrical cabinets are inefficient, requiring precise alignment and tools for assembly, and often result in lost screws during disassembly, leading to time and financial losses.
Innovation Solution
A fixing wedge made of deformable synthetic material with U-shaped notches and a central housing that accommodates cylindrical radial protrusions, allowing for tool-free pre-positioning and assembly of components, and preventing loss during disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If self-tapping screws are used to fix panels to the frame, then the panels can be securely attached, but the assembly process becomes complex requiring precise alignment and tools, and screws can be lost during disassembly
Solution Approach 1:
The fixing system is divided into separate functional elements: the wedge body with notches for positioning, the central housing for receiving the protrusion, and the elastic material for clamping. This segmentation allows each element to perform its specific function independently while simplifying the overall assembly process
Solution Approach 2:
The elastic material of the wedge automatically deforms and recovers to clamp the fixing member in place without requiring additional tools or fasteners. The wedge self-adjusts to hold the panel or rail securely, eliminating the need for separate screws and washers
2Strength
If self-tapping screws are used to fix panels, then secure attachment is achieved, but alignment precision is required during assembly which increases assembly time
Solution Approach 1:
The notches are pre-formed in the wedge walls at specific positions, and the central housing is pre-configured with the appropriate diameter to receive the cylindrical protrusion. These preliminary structural features automatically guide and align the fixing member during insertion, eliminating the need for precise manual alignment
Solution Approach 2:
The central housing acts as an intermediary element between the fixing member's protrusion and the wedge body. It provides a tolerance-absorbing interface that facilitates easy insertion while ensuring proper alignment, mediating between the fixed wedge structure and the moving fixing member
3Strength
If screws and washers are used to fix mounting rails, then the rails can be securely attached, but time is lost during assembly for positioning and fastening, and parts can be lost during disassembly
Solution Approach 1:
The positioning notches and clamping function are merged into a single wedge component. The notches provide positioning while the elastic material provides clamping, combining what would traditionally require separate positioning features and fasteners into one integrated element that performs both functions simultaneously
Solution Approach 2:
The elastic material's deformability parameter is utilized to enable tool-free assembly. The material can be temporarily deformed to allow insertion of the fixing member, then automatically recovers to provide secure clamping, changing the physical state of the material during the assembly process to achieve both ease of assembly and secure attachment
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
Facilitates easy assembly and disassembly of electrical cabinet components without tools, ensuring accurate alignment and reducing the risk of lost parts, thereby saving time and resources.
Implementation Method 1
the wedge being made of a material capable of elastically deforming under the action of an operator
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A fixing wedge (18) for receiving a fixing member with a cylindrical radial protrusion, the fixing wedge comprising a first wall (50) in which a first U-shaped notch (62) is formed, and a second wall (52) in which a second U-shaped notch (64) is formed, the first and second walls being superimposed and orthogonal to a principal axis (A72) of the wedge. The first and second notches are of similar shapes and are aligned along the principal axis, each notch having an internal edge (66) defining a mouth (68) and a rounded, circular base centered on the principal axis. The wedge further includes a curved U-shaped partition (74) which connects the first wall to the second wall by extending parallel to the main axis and set back from the inner edge of the notches, the curved partition defining a central housing (84) aligned with the first and second notches.The central housing comprises a front opening (78) and a base (82), the front opening having a width (L78) greater than the width (L68) of the opening (68) of the U-shaped notches, the curved partition having a recess (80) formed within the thickness of the curved partition (74) which widens the central housing (84) relative to the front opening (78). The recess has a cylindrical shape coaxial with the main axis (A72) and a diameter greater than the width (L78) of the front opening (78).