LED Assembly Structure with Limiting Member for Angular Positioning
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Solution Overview
Problem
Conventional shaft-hole assemblies lack rotational positioning limitations, leading to uneven brightness in light-emitting diodes due to varying assembly angles.
Innovation Solution
An assembly structure that includes a working element, a housing, and a limiting member with pins and abutting portions to restrict rotation, ensuring the working element, such as a light-emitting diode, is fixed at a predetermined angle by using a positioning holder and cables to abut against the limiting member's convex and abutting portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional shaft-hole assembly is used without rotational positioning limitations, then the assembly process is simple and fast, but the working element (light-emitting diode) exhibits uneven brightness due to varying assembly angles
Solution Approach 1:
The limiting member is pre-installed on the housing with convex members positioned at specific angles before the working element is assembled. This preliminary positioning action ensures that when the working element is inserted, its pins automatically align with the convex members, achieving precise angular positioning without requiring complex adjustment procedures during assembly, thus maintaining high assembly speed while improving angle precision
Solution Approach 2:
The convex members on the limiting member serve as intermediary elements between the housing and the working element. These convex members engage with the pins of the working element to transmit and constrain the rotational position, acting as a mediator that translates the geometric constraint into precise angular positioning, thereby achieving uniform brightness without complicating the overall assembly structure
2Manufacturing precision
If a limiting member with convex members is added to restrict rotation, then the assembly angle precision is improved, but the device complexity increases
Solution Approach 1:
The limiting member is designed to perform multiple functions: it provides rotational positioning through convex members, structural support through the supporting plate, and location constraint through the abutting member against the housing side wall. By integrating these multiple functions into a single component, the design achieves precise angular positioning without proportionally increasing device complexity, as the limiting member replaces what would otherwise require multiple separate positioning and support elements
Solution Approach 2:
The convex members are positioned asymmetrically on the limiting member at specific angles rather than being uniformly distributed. This asymmetric arrangement is optimized to provide the required angular positioning for the working element, allowing precise control of rotation while using minimal numbers of convex members, thus achieving high positioning precision without excessive structural complexity
3Ease of operation
If the working element is allowed to rotate freely, then the assembly process is easier and faster, but the light appearance becomes uneven due to rotation
Solution Approach 1:
The working element's own pins serve the dual purpose of electrical connection and rotational positioning. When the working element is inserted into the housing, its pins automatically engage with the convex members on the limiting member, causing the working element to self-position at the correct angle without requiring external alignment tools or complex adjustment mechanisms, thereby maintaining ease of operation while ensuring uniform light appearance
Solution Approach 2:
The limiting member is segmented into distinct functional features: convex members for rotational positioning, supporting plate for structural support, and abutting member for location constraint. This segmentation allows each feature to perform its specific function efficiently, with the convex members specifically addressing the light appearance uniformity issue by constraining rotation, while the overall assembly process remains simple and fast
Data Source
AI summary
An assembling structure includes a working element, a housing and a limiting member. The working element includes first and second pins. The housing includes an opening. The working element is located in the opening. The first and second pins of the working element extend toward an interior of the housing. The limiting member is connected to the housing. The limiting member includes a supporting plate and a convex member. The convex member includes a first abutting portion and a second abutting portion. The first pin and the second pin respectively abut against the first abutting portion and the second abutting portion.