Pendulum Laser Universal Joint via Injection Molding
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Solution Overview
Problem
Existing pendulum laser devices require complex assembly of individually machined components with high precision, leading to increased production time and cost due to the need for precise alignment and adjustment of ball bearings and guides.
Innovation Solution
A method for producing a pendulum arrangement using plastic injection molding, where a universal joint with microstructured shafts is formed, bearing shells are placed on these shafts, and an optics carrier is overmolded to create a self-lubricating, integrally connected unit that can rotate freely, reducing the number of assembly steps and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods with multiple individual components are used, then manufacturing precision can be achieved through high-precision machining of ball bearings and guides, but device complexity and production time increase significantly
Solution Approach 1:
The patent merges multiple separately produced components (pendulum body, universal joint, bearing shells, guides) into a single integrally molded plastic component. This combining eliminates the need for complex assembly of individually machined parts while maintaining the required alignment precision through the injection molding process itself, which can achieve tight tolerances in a single manufacturing step.
Solution Approach 2:
The injection molded component serves multiple functions simultaneously: it provides the pendulum body structure, contains the universal joint mechanism, incorporates the bearing shells, and includes the guiding elements. This multi-functionality reduces the overall component count and assembly complexity while maintaining the precision required for optical leveling signals.
2Ease of manufacture
If multiple separately produced components are assembled, then flexibility in component production is maintained, but production time and assembly steps increase
Solution Approach 1:
By combining all components into a single injection molded part, the production process is streamlined from multiple sequential manufacturing and assembly steps into a single high-speed molding operation. This dramatically increases productivity while the injection molding process itself remains flexible enough to accommodate design variations and customizations.
3Manufacturing precision
If high-precision machining is used for ball bearings and guides, then alignment accuracy of optical components is ensured, but manufacturing cost and production time increase
Solution Approach 1:
The patent replaces traditional mechanical machining processes with injection molding technology. The injection molding process inherently provides the necessary precision for alignment through mold design and control, eliminating the need for subsequent machining operations and manual adjustment of ball bearings and guides, thereby improving production efficiency while maintaining alignment accuracy.
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 method simplifies the production process, reduces production tolerances, and eliminates the need for elaborate machining and adjustment, resulting in a more efficient, cost-effective, and precise pendulum laser device with minimal components.
Implementation Method 1
The shafts (50a, 50b) are produced at least partially with a microstructure (68), in particular with a surface capillary structure (68'), which serves to hold a lubricant
Implementation Method 2
the injected plastic material is hardened
Data Source
AI summary
A method for producing a pendulum arrangement of a pendulum laser device includes producing a universal joint of a pendulum of the pendulum arrangement by forming two orthogonal, at least partially micro-structured shafts via plastic injection moulding and positioning at least two bearing shells on the at least partially micro-structured regions of at least one shaft of the universal joint. The method further includes producing an optic carrier of the pendulum of the pendulum arrangement as a single piece with the bearing shells by overmoulding at least two bearing shells surrounding a shaft of the universal joint via plastic injection moulding. The optic carrier is connected to the universal joint such that it is configured to rotate about the one shaft.