Modular Padlock with Interchangeable Housing and Shackle
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Solution Overview
Problem
Existing padlocks for securing industrial plant switches require significant inventory investments and slow delivery of custom configurations due to numerous design variations, and they do not allow for easy modification of the exterior design without affecting the internal locking mechanism.
Innovation Solution
A modular padlock design featuring a lock body with interchangeable housing and shackle, where the housing can be extended with a reception groove for a longer length, enabling easy assembly and modification of the padlock's exterior while maintaining the same internal locking mechanism, and allowing for cost-effective production and quick adaptation to different configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple design variations of padlocks are produced to meet different customer requirements (length, color, shackle engagement, cylinder configuration), then customer-specific needs are satisfied, but inventory investment increases enormously and delivery time increases
Solution Approach 1:
The padlock is divided into separate modular components: a standardized lock body and interchangeable exterior elements (housing, shackle, cylinder). This segmentation allows the lock body to remain uniform while exterior components vary to meet different customer requirements, dramatically reducing inventory needs while maintaining design flexibility.
Solution Approach 2:
The standardized lock body serves as a universal base that can accommodate multiple types of exteriors (different lengths, colors, shackle configurations, cylinder types). This multi-functionality allows a single lock body design to fulfill various customer specifications through component interchangeability, eliminating the need to produce entirely different padlock versions.
2Adaptability or versatility
If the exterior design of the padlock is modified to meet customer requirements, then design flexibility is achieved, but the internal locking mechanism must be redesigned and retested
Solution Approach 1:
The padlock structure is segmented into independent functional modules: the lock body containing the locking mechanism is separated from the exterior components (housing, shackle, cylinder). This allows exterior modifications without affecting the internal mechanism, as each module can be developed, tested, and modified independently.
Solution Approach 2:
The exterior components are extracted as separate interchangeable elements that can be modified without altering the core locking mechanism. This extraction allows customers to specify different exterior configurations while the standardized lock body remains unchanged, simplifying the modification process.
3Productivity
If a standardized padlock design is used, then production cost is reduced and delivery is faster, but custom configurations cannot be provided
Solution Approach 1:
The padlock is segmented into a standardized core (lock body) and customizable exterior components. This allows the standardized portion to be produced efficiently in volume for fast delivery, while the exterior components can be selected or configured to meet specific customer requirements without slowing production.
Solution Approach 2:
The standardized lock body serves as a universal platform that can support multiple exterior configurations. This universality enables fast delivery of the core component while allowing customization through interchangeable exteriors, combining the benefits of standardization and customization.
4Ease of operation
If the padlock allows free opening in any direction, then ease of operation is improved, but unnecessary engagement with plant parts may occur causing safety issues
Solution Approach 1:
The shackle engagement mechanism is designed with asymmetric geometry that permits opening motion only in the intended direction away from the plant. The reception groove and shackle shape are configured so that opening in the correct direction clears plant parts, while opening in other directions would cause interference, thereby preventing accidental activation.
Solution Approach 2:
The reception groove acts as an intermediary element that guides the shackle's opening motion along a controlled path. This intermediary structure ensures the shackle opens in a predetermined direction that avoids contact with plant parts, while still allowing sufficient freedom of operation for the user.
Data Source
AI summary
The invention relates to a padlock in particular to a padlock for securing and monitoring a switch of an industrial plant. The invention further relates to a set of padlocks, to a padlock housing and to a method of retrofitting a padlock.