Roller shutter box integral lug fastening mechanism
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Solution Overview
Problem
Existing methods for assembling and disassembling rolling shutter side panels to central boxes are time-consuming, lack precision, and require manual labor, leading to inefficiencies and increased economic costs due to the need for multiple fasteners and lack of automation.
Innovation Solution
The use of deformable lugs, such as L-shaped and trapezoidal tabs, which are deformed to securely attach side panels to a central box without additional external components, allowing for automated assembly and disassembly with precise positioning and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screw and/or rivet type fasteners are used to secure flanges to boxes, then the fixing method is universal and easy to implement, but the assembly precision deteriorates and manual operations take time
Solution Approach 1:
The fixing mechanism is segmented into integral lugs that are pre-formed as part of the box structure itself, rather than using separate fasteners. This segmentation allows the lugs to be precisely positioned during box formation, ensuring high assembly precision while maintaining ease of implementation through the integral design.
Solution Approach 2:
The lugs are merged with the box structure as integral components, eliminating the need for separate fasteners. This merging ensures that the positioning features are built-in with high precision during box manufacturing, while the simple lug deformation mechanism keeps the implementation easy and automated.
2Reliability
If multiple fasteners are used to secure flanges to boxes, then the fixing reliability is improved, but the assembly time increases and automation becomes difficult
Solution Approach 1:
The lugs are designed to be deformed and bent into the flanges during assembly, performing the fixing function through their own structural transformation rather than requiring separate fastening operations. This self-service mechanism ensures reliable fixing while enabling automated assembly processes, as the deformation can be easily performed by automated bending tools.
Solution Approach 2:
The lugs undergo a parameter change from a straight or initial configuration to a deformed configuration that engages with the flange. This parameter change (shape transformation) provides reliable mechanical interlocking while the simplicity of the deformation process allows for easy automation, improving both reliability and assembly speed.
3Manufacturing precision
If manual fixing operations are used to attach cheeks to boxes, then the precision of assembly can be maintained, but the intervention time and labor costs increase
Solution Approach 1:
The lugs undergo controlled deformation through bending to achieve the fixed position, transforming from a pre-formed state to an engaged state. This parameter change can be precisely controlled through automated bending processes, maintaining assembly precision while dramatically reducing the time required compared to manual fastener installation.
Solution Approach 2:
The traditional mechanical fastening system (screws, rivets requiring manual manipulation) is replaced with a deformation-based system where the lugs are bent into place. This substitution eliminates complex manual operations while maintaining precision through controlled deformation, enabling automation and reducing assembly time.
4Reliability
If additional external fixing components are used, then the fixing function is improved, but the device complexity and material requirements increase
Solution Approach 1:
The fixing components (lugs) are merged with the box structure as integral parts, eliminating the need for additional external fixing components. This merging simplifies the overall system by reducing the number of separate parts, while the lug deformation mechanism provides sufficient fixing function for the application.
Solution Approach 2:
The fixing function is extracted from the box structure and embodied in the integral lugs, which are then deformed to provide the necessary attachment. This extraction creates a dedicated fixing mechanism that is simpler than adding external components, while maintaining reliable fixing functionality through the deformation-based engagement.
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 solution significantly reduces assembly time, ensures high precision, eliminates material loss, and achieves an attractive aesthetic appearance while minimizing human intervention and additional materials, resulting in efficient and cost-effective roller shutter box production and maintenance.
Implementation Method 1
the deformation of the tab is then carried out by rotation around this segment
Implementation Method 2
The mere existence of lugs to be deformed also allows, if desired, the implementation of an automation which firstly requires a relative positioning of the cheeks and the box and secondly the deformation of the lugs for blocking cheeks in the box
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a roller shutter box with a central casing 1 and lateral end plates 20, said end plates 20 being oriented in a plane substantially perpendicular to the longitudinal axis of the casing 1 and embedded in the axial ends of the casing 1, with mutual fastening means provided between them. These fastening means comprise a tab 10, 11, 12 for each wall 2, 3, 4 of the casing 1, obtained by cutting into a wall 2, 3, 4 of the casing 1 and deformed inwards from the casing 1 substantially parallel to the longitudinal axis of the casing 1 in order to cooperate with a recess 18 opening into the periphery of the end plate 20, each tab 10, 11, 12 and the recess 18 having, at the end of the deformation, opposing faces 16 oriented to lock each end plate 20 in the casing 1, at least in translation in a direction parallel to the longitudinal axis of the casing 1.