LED Lamp Holder Base with Axial Symmetry and Directional Indicator
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Solution Overview
Problem
The existing LED lamp holders require manual assembly due to structural limitations, leading to potential errors and inefficiencies in automated mass production, which affects the yield and consistency of the product.
Innovation Solution
The design includes a base with axially symmetric casing, cover, and tail plug, featuring latch members and channels for precise alignment, allowing for automated assembly and ensuring waterproof and dustproof sealing of the LED luminaire, reducing the complexity of alignment and enabling the use of automated equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the base structure is designed with specific alignment requirements for the LED luminaire, then the LED luminaire can be properly positioned and electrically connected, but manual assembly is required which reduces productivity and increases error rates
Solution Approach 1:
The patent applies asymmetry by introducing a directional indicator structure on the LED luminaire that corresponds to a specific insertion direction in the base. This asymmetric feature guides the assembly process, ensuring proper alignment while enabling automated assembly. The indicator structure creates a unique orientation that prevents incorrect insertion, resolving the contradiction between precision and productivity.
Solution Approach 2:
The patent implements self-service through the directional indicator structure that automatically guides the LED luminaire into the correct position during assembly. The indicator and its corresponding receptacle on the base work together to self-align the components without requiring manual intervention or complex alignment procedures, thereby enabling automated assembly while maintaining precision.
2Reliability
If manual assembly is used to ensure proper alignment, then assembly errors are reduced, but labor costs increase and productivity decreases
Solution Approach 1:
The asymmetric directional indicator structure provides built-in guidance that ensures correct assembly orientation. This design feature inherently prevents assembly errors by making incorrect insertion physically impossible or easily identifiable, thereby maintaining high reliability while enabling automated high-speed assembly processes.
Solution Approach 2:
The self-aligning indicator structure performs the alignment function automatically during the assembly process. The LED luminaire's indicator naturally guides itself into the correct position relative to the base's receptacle, eliminating the need for manual alignment operations and ensuring consistent accuracy across all assembled units.
3Extent of automation
If the base components are designed as axially symmetric structures, then automated assembly becomes feasible, but alignment complexity increases
Solution Approach 1:
While the base components maintain axial symmetry for automated assembly compatibility, the patent introduces a directional indicator structure that breaks the symmetry in a controlled manner. This asymmetric feature provides clear alignment information without complicating the overall symmetric design, allowing automated systems to efficiently assemble the components while maintaining precise orientation.
Data Source
AI summary
A lamp holder for an LED lamp string includes a base and an LED luminaire. The LED luminaire is inserted into the base. The base includes a casing, a cover, and a tail plug which are axially symmetric structures. The combination of the casing, cover and tail plug form a pin insertion hole of the LED luminaire and a wire inserting hole of a connecting wire of the lamp string, and the three are combined as a whole by a latch member, a latch slot, and a latch member. The cover and the tail plug seal an electrically conductive portion of the LED luminaire to provide a waterproof and dustproof effect. Since the casing, cover and tail plug are bilaterally symmetric structures, the level of difficulty of the alignment is reduced significantly. Automated equipment may be used for assembling the base in mass production, and the labor is reduced significantly.