Engine Controller Covering Member Rust Prevention
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Solution Overview
Problem
Engine controllers with cheap, iron-based metal plates for covering members tend to rust at the outer peripheral edges, compromising their commercial value and requiring costly surface treatments to prevent corrosion, which increases manufacturing costs.
Innovation Solution
An engine controller design featuring an aluminum die-cast main case body with a covering member made of an iron-based metal plate, where a liquid or jellied water-proofing adhesive is used to hermetically seal the open top, covering the entire outer peripheral edge face and providing additional sealing between the main case body and the covering member, preventing rust without increasing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plated steel plate is used for the covering member to reduce manufacturing cost, then the manufacturing cost is reduced, but the outer peripheral edge face tends to rust due to lack of plating coverage
Solution Approach 1:
A water-proofing adhesive is introduced as an intermediary substance between the main case body and the covering member. This adhesive coats the outer peripheral edge face of the covering member, providing rust protection without requiring additional plating processes. The adhesive serves as a mediator that protects the exposed cut surface while maintaining the cost benefits of using a plated steel plate covering member
Solution Approach 2:
The water-proofing adhesive is applied in advance to the outer peripheral edge face of the covering member before the covering member is assembled to the main case body. This preliminary coating ensures that the vulnerable cut surface is protected from rust before it is exposed to the external environment, preventing corrosion rather than treating it after occurrence
2Reliability
If plating is applied to the outer peripheral edge face in a subsequent process to prevent rust, then the rust resistance is improved, but the manufacturing cost increases
Solution Approach 1:
The water-proofing adhesive serves as a cost-effective intermediary alternative to additional plating processes. It provides the necessary rust protection for the outer peripheral edge face without requiring expensive subsequent plating operations, thereby maintaining manufacturing cost efficiency while achieving the desired reliability
Solution Approach 2:
The invention uses a relatively inexpensive water-proofing adhesive instead of expensive subsequent plating processes. The adhesive provides sufficient protection for the covering member's outer peripheral edge face at a lower cost, accepting that it may need replacement or reapplication rather than providing permanent protection like plating would
3Reliability
If aluminum is used in place of iron-based material for the covering member to prevent rust, then the rust resistance is improved, but the manufacturing cost increases
Solution Approach 1:
Instead of changing the material of the entire covering member to aluminum, the invention applies local protection only where needed - the water-proofing adhesive is applied specifically to the outer peripheral edge face where plating is not present and rust is most likely to occur. This localized approach maintains the cost benefits of using iron-based material while providing rust protection at the vulnerable area
Solution Approach 2:
The invention changes the protective parameter from material composition (aluminum vs. steel) to surface treatment (adhesive coating). By applying a water-proofing adhesive coating to the outer peripheral edge face, the invention achieves rust protection through a surface parameter change rather than changing the base material, thereby maintaining manufacturing cost efficiency
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 design effectively prevents rust on the outer peripheral edge of the covering member while maintaining water-proofness and dust-proofness, even in severe environments, thereby reducing manufacturing costs and enhancing the reliability of the engine controller.
Implementation Method 1
a water-proofing adhesive is interposed between the main case body and the covering member
Implementation Method 2
hermetically seal the interior of the main case body
Implementation Method 3
the covering member being fixedly clamped to the main case body by means of a setscrew
Data Source
AI summary
There is proposed an engine controller which is excellent in reliability in that the outer peripheral edge face (cut surface) of covering member can be prevented from being rusted while securing the water-proofness and dust-proofness. This engine controller comprises a circuit board (12) for controlling an engine; an aluminum die-cast main case body (20) having an open top; and a covering member (30) made of an iron-based metal plate which is preliminarily applied with surface treatment, the covering member (30) being fixedly clamped to the main case body (20) by means of a setscrew (40) so as to hermetically close the open top of the main case body (20); wherein the main case body (20) is provided thereon with a pedestal (24) or groove (25) on which a liquid or jellied water-proofing adhesive (50) is coated or filled (piled), thereby enabling entire outer peripheral edge face (33a) of the covering member (30) to be covered by the water-proofing adhesive (50).