Integral Cam Padlock Design for Compact Locking Mechanisms
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional padlocks with key-actuated locking mechanisms often require additional space due to cam components, resulting in longer and larger designs, particularly when using radially-actuated tumblers, which limits their use in tight spaces.
Innovation Solution
A linear padlock design with an integral cam connected to the lock cylinder, reducing overall length and eliminating the need for additional components, allowing for a more compact form factor and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cam component is added to the locking mechanism, then the locking functionality is improved, but the overall length of the padlock increases
Solution Approach 1:
The cam component is integrated directly into the lock cylinder as a single piece, eliminating the need for separate cam and lock cylinder components. This merging reduces the overall axial length of the locking mechanism while maintaining all necessary locking functionalities including the cam's ability to move blocking elements and engage the shackle.
Solution Approach 2:
The cam component is positioned within the lock body's internal cavity, nested alongside the lock cylinder and tumblers. This nested arrangement allows the cam to occupy space efficiently within the existing structure rather than extending the overall padlock length, as the cam operates within the same axial envelope as the other locking components.
2Reliability
If additional lock cylinder pieces are used, then the locking mechanism functionality is improved, but the device complexity increases
Solution Approach 1:
The cam and lock cylinder are combined into a single integrated component, reducing the total number of parts in the locking mechanism. This integration maintains all necessary functionalities (key actuation, cam rotation, blocking element movement) while eliminating the need for separate mounting features, fasteners, and alignment mechanisms that would be required for multiple discrete components.
Solution Approach 2:
The integrated lock cylinder-cam component performs multiple functions simultaneously: it serves as the key-receiving cylinder, the rotating cam that moves blocking elements, and the structural element that retains tumblers and springs. This multi-functionality eliminates the need for specialized separate components for each function, simplifying the overall device.
3Reliability
If multiple separate components are used in the locking mechanism, then the functionality is improved, but the manufacturing time and costs increase
Solution Approach 1:
The lock cylinder and cam are manufactured as a single integrated component, which can be produced in one machining or molding operation rather than requiring separate manufacturing, precision alignment, and assembly steps. This significantly reduces manufacturing complexity, assembly time, and the potential for assembly errors, leading to lower production costs and higher productivity.
Data Source
AI summary
A padlock with an associated locking mechanism is configured for use in a lock configured to be locked and unlocked by a key. The locking mechanism includes a lock cylinder with a key-receiving end configured to interface with the key and further includes a cam positioned at an axial end of the lock cylinder opposite the key-receiving end thereof. The cam is integrally connected thereto thereby restricting axial and rotational motion of the cam with respect to the lock cylinder and can be used to retain components of the locking mechanism (such as tumblers and springs) in the lock cylinder.