Metal Frame Assembly Positioning for Image Formers
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Solution Overview
Problem
The existing methods for manufacturing metal frames of image forming apparatuses, such as electrophotographic copying machines, face challenges in maintaining position accuracy due to dimensional tolerances in the formation of protrusions, bulging portions, and openings, which affect the assembly and welding of metal plates, leading to deteriorated image quality.
Innovation Solution
A method involving the use of jigs with positioning pins and insertion portions to precisely assemble and fix metal plates, ensuring accurate positioning before welding, thereby minimizing the impact of tolerances and maintaining high position accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal plates are assembled using protrusions and openings with dimensional tolerances, then the assembly process is simple, but the position accuracy deteriorates
Solution Approach 1:
A positioning pin is introduced as an intermediary component between the first and second metal plates. The positioning pin fits into a positioning hole in the first metal plate and abuts against a bulging portion in the second metal plate, serving as a mediator that establishes precise positional relationship without requiring high-precision fitting between the metal plates themselves
Solution Approach 2:
The positioning pin is inserted into the positioning hole before the metal plates are fixed together by welding. This preliminary positioning action establishes the correct relative position of the metal plates prior to the fixing process, ensuring accurate alignment is maintained during subsequent operations
2Productivity
If dimensional tolerances are accepted in forming metal plates, then manufacturing cost and time are reduced, but frame accuracy deteriorates
Solution Approach 1:
The positioning pin acts as a mediator that decouples the dimensional tolerance requirements from the final assembly accuracy. The metal plates can be manufactured with standard tolerances, and the positioning pin compensates for these tolerances by providing a precise定位 interface
Solution Approach 2:
The invention changes the critical parameter for position accuracy from the dimensional parameters of the metal plates themselves to the dimensional parameters of the positioning pin and positioning hole. This parameter transformation allows tolerances to be managed in a more controllable manner
3Strength
If metal plates are fixed by welding in assembled state, then structural strength is improved, but position accuracy is affected by formation tolerances
Solution Approach 1:
The positioning pin is installed before welding to establish the correct relative position of the metal plates. This preliminary positioning ensures that when the plates are welded in their assembled state, they maintain the accurate positional relationship established by the positioning pin
Solution Approach 2:
The positioning pin serves as a temporary intermediary that guides the welding process. By maintaining the correct spatial relationship between the metal plates during the welding operation, it ensures that the structural strength gained from welding does not compromise position accuracy
Data Source
AI summary
A method of manufacturing a metal frame of an image forming apparatus includes assembling a first support, a second support, and a connecting member using a first jig having a base portion, whereafter there is a positioning of a position where the first support, the second support, and the connecting portion are fixed using a second jig having an insertion portion. In the first support, the insertion portion is inserted into a hole portion formed in a second metal plate so that the second metal plate moves upward in the vertical direction with respect to a first metal plate, and a restricting portion formed on one of the first and second metal plates abutted to the other metal plate in the assembly are separated from each other. The first support and the connecting member are fixed to each other, and the second support and the connecting member are fixed to each other.