Image Forming Apparatus Frame Assembly With Fewer Jigs
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Solution Overview
Problem
The existing method of joining metal plates in image forming apparatus frames using multiple jigs is inefficient in terms of cost and workability, as it requires individual jigging for each plate, increasing complexity and reducing productivity.
Innovation Solution
A method involving a first support, a second support, and a connecting member that allows provisional assembly on a jig, followed by engagement and fixing of the connecting member to reduce the need for multiple jigs, enabling self-standing assembly of the frame before joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If each metal plate is held one at a time by a jig for positioning before joining, then the positional accuracy of each metal plate is guaranteed, but the number of jigs increases and manufacturing efficiency decreases
Solution Approach 1:
The patent combines multiple metal plates (first support, second support, and connecting member) into a single provisional assembly unit that can be positioned together on one jig. The connecting member engages with both supports to form a rigid structure that maintains relative positions, allowing all components to be positioned and joined using a single jig rather than multiple separate jigs for each plate.
Solution Approach 2:
The patent performs preliminary provisional assembly of the metal plates on the jig before final joining. The connecting member is temporarily engaged with both supports to establish correct positional relationships, and this provisional structure is then used as the basis for final welding or screwing, ensuring accuracy while reducing jig requirements.
2Manufacturing precision
If multiple jigs are used to hold each metal plate individually, then positioning accuracy is maintained, but manufacturing cost and workability deteriorate
Solution Approach 1:
The patent merges multiple positioning operations into a single jig by creating a provisional assembly where the connecting member links both supports. This allows one jig to perform the positioning function that previously required multiple separate jigs, reducing both equipment cost and operational complexity.
Solution Approach 2:
The provisional assembly structure itself serves as the positioning mechanism. The connecting member and supports form a self-contained unit that maintains its own geometry and relative positions during assembly, reducing reliance on external fixing devices and simplifying the manufacturing process.
3Manufacturing precision
If individual jigs are used for each metal plate, then assembly precision is ensured, but productivity decreases due to increased complexity
Solution Approach 1:
The patent combines multiple assembly operations into a single workflow by creating a provisional assembly that can be positioned and joined in one continuous process using one jig. This eliminates the need to repeatedly load and position separate plates on multiple jigs, significantly improving throughput while maintaining precision through the rigid connecting structure.
Data Source
AI summary
A method for manufacturing a metal frame of an image forming apparatus that is provided with a first support, a second support that is spaced apart from the first support and that supports an image forming unit together with the first support, and a connecting member that connects the first support and the second support, the method including: a first step of erecting the first support on a base portion, which is a first step of provisionally assembling the first support on a jig that has a base portion and a support portion erected on the base portion; a second step of achieving provisional assembly by placing the connecting member on the support portion of the jig and, through engagement between the first support and the connecting member, causing the connecting member to be supported by the first support and the support portion; a third step of engaging the connecting member and the second support; and a fixing step of fixing the first support and the connecting member and fixing the second support and the connecting member.