Modular Lock Plug Cartridge for Interchangeable Core Assembly
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Solution Overview
Problem
Traditional interchangeable core lock cylinders face difficulties in pinning due to complex part tolerances and a tendency to 'explode' when the plug is removed, leading to loss or damage of internal components.
Innovation Solution
A modular locking plug system composed of cartridges with a mounting device and biasing members, allowing for easier assembly and re-pinning by aligning key passages and using cam surfaces to maintain component position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional interchangeable core assemblies are used, then the lock cylinder can function with proper tolerances and pinning, but the assembly tends to explode when the plug is removed from the shell
Solution Approach 1:
The lock cylinder is divided into modular components: a shell, a plug, and interchangeable core assemblies that can be independently handled. The core assembly is further segmented into a housing and a cartridge that can be separated. This segmentation allows the cartridge to be removed and reinserted without causing the entire assembly to explode, as the modular design contains components within their respective modules.
Solution Approach 2:
A retaining structure acts as an intermediary between the plug and the core assembly components. This retaining structure prevents the springs and internal components from being ejected when the plug is removed, serving as a mediator that controls the release of components and prevents the harmful explosion effect while still allowing legitimate disassembly and reassembly.
2Reliability
If traditional pinning processes are used, then the lock cylinder achieves proper functionality, but the pinning process becomes difficult and laborious
Solution Approach 1:
The pinning process is segmented into modular steps where the core assembly is pinned as a complete unit before being installed in the plug. The cartridge is pinned to the housing in a controlled environment, and then the entire core assembly is installed as one piece. This eliminates the need for complex field pinning operations and reduces manufacturing labor while maintaining security functionality.
Solution Approach 2:
The core assembly is pre-pinned in the housing before final installation into the plug. All critical pinning operations are completed in advance during manufacturing, allowing for proper tolerances and secure assembly. This preliminary action eliminates the need for difficult field pinning operations and ensures reliable locking functionality from the start.
3Ease of repair
If the plug is removed from the shell, then the lock cylinder can be serviced or reconfigured, but internal components are ejected and lost
Solution Approach 1:
The cartridge is extracted as a complete, self-contained unit from the core assembly housing. This extracted cartridge can be removed from the plug and reinserted without affecting other components. The retaining structure ensures that when components are taken out for servicing, they are removed in an controlled manner rather than being ejected, preventing loss while enabling serviceability.
Solution Approach 2:
The retaining structure serves as an intermediary that controls component release during servicing operations. It allows the plug to be removed from the shell for serviceability while preventing the ejection and loss of internal components like springs and pins, thereby enabling maintenance without component loss.
4Reliability
If complex tolerances are maintained for proper pinning, then the lock cylinder functions correctly, but the assembly process becomes more complex
Solution Approach 1:
The assembly is segmented into modular units (shell, plug, core assembly, housing, cartridge) that can be manufactured and pinned separately with controlled tolerances. Each module maintains proper pinning accuracy independently, reducing the overall assembly complexity while preserving reliable locking functionality through standardized interfaces between modules.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies the pinning process, reduces the risk of component loss or damage, and allows for customizable lock cylinder configurations, enhancing both manufacturing efficiency and field maintenance.
Implementation Method 1
a biasing member configured to apply pressure to the cartridge
Implementation Method 2
The rod includes a cam surface configured to translate rotation of the plug into axial displacement of the rod
Data Source
AI summary
An exemplary locking cartridge includes a generally cylindrical housing, first and second plates, and a sliding member. The plates are rotatable with respect to the housing, and at least one of the plates is movable in the axial direction of the housing. The housing and the movable plate include cam surfaces that interact to cause the movable plate to move toward the other plate when the movable plate is rotated. The sliding member is slidingly coupled to one of the plates and operable in a blocked state in which the sliding member resists axial motion of the movable plate, and an unblocked state in which the sliding member does not resist axial motion of the movable plate.