Electrical Box Bar Hanger Locking Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current electrical box bar hangers face challenges in attaching end plates perpendicularly to the channel, requiring costly and difficult welding operations, which can lead to quality issues during production.
Innovation Solution
An adjustable channel with locking tabs and apertures allows end plates to be bent 90 degrees and secured without welding, using swageable locking tabs that align with apertures to maintain perpendicularity, eliminating the need for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to attach end plates to the channel, then the end plates can be securely attached, but the manufacturing process becomes costly and difficult with quality issues
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical locking system using locking tabs and locking apertures. The locking tabs extend from the channel and engage with locking apertures in the end plates through a swaging process, eliminating the need for welding while maintaining secure attachment and improving manufacturing ease.
2Ease of manufacture
If welding is used to attach end plates to the channel, then the end plates can be attached to the channel, but the end plates may not be perpendicular to the channel after welding
Solution Approach 1:
The patent incorporates preliminary action by pre-forming the locking tabs on the channel and pre-positioning the locking apertures on the end plates before assembly. The locking tabs are designed with specific geometry and the swaging process is pre-programmed to bend the end plates to the exact angle needed, ensuring perpendicularity is achieved automatically during the attachment process rather than requiring post-welding adjustment.
3Ease of manufacture
If welding is used to attach end plates to the channel, then the attachment can be made, but the process must be repeated until the end plates are attached perpendicular to the channel
Solution Approach 1:
The patent replaces the welding process with a mechanical locking system that achieves perpendicular attachment in a single swaging operation. The locking tabs and locking apertures are designed to guide the end plates into the correct perpendicular position during assembly, eliminating the need for repeated welding and inspection cycles.
Solution Approach 2:
The locking mechanism is designed to be self-aligning and self-positioning. When the end plates are attached to the channel, the locking tabs automatically engage with the locking apertures in a manner that inherently positions the end plates perpendicular to the channel, without requiring external intervention or repeated adjustments.
Data Source
AI summary
An electrical box bar hanger includes an adjustable channel having a plurality of locking tabs at distal ends thereof and first and second end plates with each of the first and second end plates having a plurality of locking apertures thereon. The first and second end plates are integrally connected to each distal end of the adjustable channel. When each end plate is bent 90 degrees against each corresponding end of the adjustable channel, each of the plurality of locking apertures aligns with each corresponding locking tab, such that the plurality of locking tabs can be inserted into corresponding locking aperture to allow the first and second end plates to be perpendicular with the adjustable channel without the use of welding.