Image Forming Apparatus Frame Laser Welding Precision
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Solution Overview
Problem
The challenge in manufacturing a highly precise frame member for image forming devices is the deformation caused by dimension failures during laser welding, leading to potential welding failures and difficulties in mass production.
Innovation Solution
The image forming member incorporates a frame structure with a first support member composed of a first and second member, where the second member is outside the first member in the longitudinal direction, and both are fixed to a plate member by welding, along with a third support member attached to the second plate member by welding, to maintain precise dimensions and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is used to assemble the frame member, then productivity and cost are improved, but welding failure occurs when gaps between components are large
Solution Approach 1:
The positioning member is designed with predetermined dimensions and tolerance control to pre-establish accurate spacing between components before welding. This preliminary dimensional control ensures that gaps between the stay and side plates fall within the optimal range for laser welding, preventing welding failure while enabling high-speed automated assembly.
2Manufacturing precision
If conventional screw fastening is used, then positioning precision is maintained, but productivity and cost are worsened
Solution Approach 1:
The patent replaces the mechanical screw fastening system with a laser welding system. This substitution eliminates the need for threaded holes, screws, and associated positioning features, while achieving equivalent or superior positioning precision through controlled laser welding processes combined with precision positioning members.
Solution Approach 2:
The patent changes the joining method parameter from mechanical (screw fastening) to thermal (laser welding). This parameter change enables automated high-speed assembly while maintaining precision through controlled welding parameters and precision positioning members that ensure accurate component alignment before welding.
3Ease of manufacture
If tolerance of stay length dimension is large, then ease of manufacture is improved, but deformation of frame member occurs
Solution Approach 1:
The positioning member acts as an intermediary element between the stay and side plates. It compensates for dimensional variations in the stay by providing a precisely controlled reference surface, ensuring that the final assembled frame member achieves the required precision even when the stay has larger manufacturing tolerances.
Solution Approach 2:
The positioning member is designed with predetermined dimensions that establish the correct spacing between components. By controlling the dimensions of the positioning member with high precision rather than the stay itself, the system achieves accurate frame member assembly while allowing the stay to be manufactured with more relaxed tolerances.
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 configuration enhances the structural integrity and precision of the frame member, reducing deformation and the likelihood of welding failures, thereby facilitating high-precision mass production.
Implementation Method 1
a second support member which is fastened to the first plate member by welding
Implementation Method 2
a third support member which is fastened to the second plate member by welding
Data Source
AI summary
The image forming member has a frame member which forms the image forming member, the frame member including: a first support member, the first support member having a first member and a second member which is attached to the first member, a part of the second member being outside of the first member in a longitudinal direction of the first support member, a second plate member being fixed to a first plate member so that a length of the first support member in a longitudinal direction becomes a predetermined length; a second support member which is fastened to the first plate member by welding; and a third support member which is fastened to the second plate member by welding. Thereby, the image forming member can form images with high accuracy.