Key Cylinder Device Assembly Sequence Flexibility
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Solution Overview
Problem
The existing key cylinder device assembly process is restricted by the rear-side assembly sequence, limiting the degree of freedom in assembly sequence and increasing manufacturing costs due to the need for sequential assembly of components like the lock pin, spring, and hold-down plate.
Innovation Solution
A key cylinder device with a rotor case that allows the fixing member to be held by leg portions at temporary and assembly positions, enabling the stopper pin to be assembled before the rotor and sleeve are inserted, thus allowing for a more flexible assembly sequence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lock pin, spring and hold-down plate are assembled after the inner cylinder is inserted into the outer cylinder, then the assembly sequence is restricted, but the degree of freedom in assembly sequence is reduced and manufacturing cost increases
Solution Approach 1:
The patent applies preliminary action by enabling the lock pin, spring, and hold-down plate to be assembled into the outer cylinder before the inner cylinder is inserted. The outer cylinder is designed with a through-hole and holding structure that allows these components to be pre-assembled and held in position, eliminating the restriction that required sequential assembly after inner cylinder insertion. This preliminary assembly approach increases degree of freedom in assembly sequence while maintaining proper component positioning.
2Productivity
If components are pre-assembled in a preceding process, then each step of component assembly process is shortened, but the entire assembly process is not shortened due to assembly sequence restrictions
Solution Approach 1:
The patent enables true parallel preprocessing by allowing the lock pin, spring, and hold-down plate to be assembled into the outer cylinder independently before the final assembly with the inner cylinder. The through-hole structure and holding mechanism allow these components to be prepared in advance without waiting for the inner cylinder to be in place, thereby actually shortening the total assembly time rather than just individual steps.
Solution Approach 2:
The patent segments the assembly process into independent modules: the outer cylinder with its holding structure can be prepared separately with the lock pin, spring, and hold-down plate assembled, and then this pre-assembled outer cylinder assembly can be combined with the inner cylinder. This segmentation allows parallel processing of different components, increasing overall productivity.
3Reliability
If the lock pin protrudes from the outer cylinder to block the inner cylinder, then the blocking function is achieved, but the assembly sequence is restricted and cannot be pre-assembled
Solution Approach 1:
The patent modifies the lock pin structure to include a holding portion that fits into a holding structure in the outer cylinder. This allows the lock pin to be assembled into the outer cylinder in advance through the through-hole, held in the correct position, and then the inner cylinder is inserted. The blocking function is maintained because the lock pin still protrudes from the outer cylinder to contact the inner cylinder, but the assembly sequence flexibility is improved by enabling preliminary assembly.
Data Source
AI summary
A key cylinder device includes a rotor case that encloses a rotor operable to rotate by a mechanical key, the rotor being inserted into the rotor case from a direction opposite to an insertion direction of the mechanical key, a holding member including a pair of leg portions held by the rotor case, and a fixing member that protrudes from the holding member. The rotor case includes a fixing member-holding structure that the fixing member is held by the leg portions of the holding member at a temporary assembly position for temporarily assembling the fixing member in a retracted state without inwardly protruding beyond an inner surface of the rotor case and at an assembly position for assembling the fixing member in a state of inwardly protruding from the inner surface of the rotor case.