Roll-Formed Bar Lock Assembly for Lightweight Padlock Access
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Solution Overview
Problem
Conventional bar lock assemblies are heavy, costly to manufacture, and difficult to modify, with handles that are not easily accessible for securing, and they lack the ability to accommodate standard locking devices like padlocks.
Innovation Solution
The bar lock assembly is designed with a keeper and cam made from roll-formed sheet metal, featuring laterally spaced side walls with aligned openings and a rotatable actuator shaft, allowing for easy assembly and modification to accommodate locking devices, with the cam nested between the keeper's side walls for secure engagement and disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If die-cast parts are used for keeper and cam, then strength and durability are improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent changes the material form from die-cast parts to roll-formed sheet metal, altering the physical parameters of the keeper and cam. This transformation maintains structural integrity while significantly reducing weight and manufacturing complexity, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent employs thin sheet metal components (keeper and cam) formed through roll-forming processes. These thin-film structures provide sufficient strength for locking applications while dramatically reducing weight compared to traditional die-cast parts, addressing the strength-weight tradeoff.
2Duration of action of stationary object
If die-cast parts are used for keeper and cam, then durability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent transforms the manufacturing approach from die-casting to roll-forming sheet metal. This parameter change in the manufacturing process simplifies production, reduces tooling costs, and enables easier modifications while maintaining the durability required for locking applications.
Solution Approach 2:
The patent divides the locking mechanism into separable components (keeper, cam, shaft) that can be independently manufactured and assembled. This segmentation allows for simplified manufacturing of each component and easier replacement or modification, reducing overall manufacturing complexity and cost.
3Device complexity
If conventional handle positioning is used, then structural simplicity is maintained, but accessibility for lock manipulation deteriorates
Solution Approach 1:
The patent introduces a lateral dimension to handle positioning, moving the handle away from the elevated position to a laterally accessible position. This dimensional change improves accessibility for lock manipulation while maintaining the overall structural simplicity of the locking mechanism.
4Stability of the object's composition
If conventional design is used, then structural integrity is maintained, but adaptability for locking devices deteriorates
Solution Approach 1:
The patent segments the locking mechanism into modular components (keeper with side walls, cam with engagement members, shaft) that can be independently configured. This segmentation enables easy adaptation to accommodate different locking devices while maintaining the structural integrity of each component through standardized roll-formed designs.
Solution Approach 2:
The patent designs the keeper and cam with universal features (aligned openings, engagement members) that can accommodate various locking devices. This universal design approach enables the same basic structure to adapt to different security requirements without compromising structural integrity.
Data Source
AI summary
A bar lock assembly includes a keeper having a base and a pair of laterally spaced side walls extending transversely from the base. At least one shaft extends between and is coupled to the side walls. A cam is coupled to and rotatable relative to the keeper between an engaged position and a disengaged position. The cam includes an engagement member engaged with the shaft when rotated to the engaged position. The engagement member is disengaged with the first shaft when rotated to the disengaged position. The cam may include a pair of engagement members. The keeper and/or cam may be roll formed and configured with a U-shaped cross-section.