Segmented Door Operator Housing for Cost-Effective Assembly
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Solution Overview
Problem
Conventional door operators are complex and costly to produce and assemble, with a complicated cast housing and intricate mounting systems that complicate the conversion of linear to rotational movement for door operation.
Innovation Solution
A simplified door operator design featuring a base plate with a receiving profile for easy assembly of shaft and cylinder housings, a driven shaft, and a piston with an energy accumulator, allowing for mutual conversion between linear and rotational movements, and various connection methods for fluid-tight and secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cast housing is used to mount the driven shaft and piston, then the door operator achieves reliable function, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The cast housing is divided into separate modular components: a base plate, a shaft housing containing the driven shaft, and a cylinder housing containing the piston. These separate components are assembled together using standardized connection methods, eliminating the need for a single complex cast housing while maintaining structural integrity and reliability.
2Reliability
If a cast housing with bearing-mounted driven shaft and piston is used, then the door operator functions reliably, but the production and assembly cost increase
Solution Approach 1:
The housing is segmented into separate components that can be manufactured using simpler, more cost-effective processes such as sheet metal forming or plastic injection molding, rather than requiring complex castings. This segmentation allows each component to be produced independently and assembled, reducing overall manufacturing cost.
Solution Approach 2:
The base plate serves multiple functions: it provides mounting surfaces for the shaft housing and cylinder housing, acts as a structural support element, and facilitates installation to various surfaces (walls, frames, door leaves). This multi-functionality reduces the need for additional specialized components, lowering production costs.
3Force
If the door operator is fastened directly to the door leaf, then the force transmission is direct, but the assembly complexity increases due to linkage requirements
Solution Approach 1:
The mounting function and the force transmission function are merged into the base plate and housing assembly. The housing components themselves serve as the mounting structure, eliminating the need for separate linkage mechanisms when mounted directly to the door leaf, thereby simplifying the overall system while maintaining direct force transmission.
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
The solution results in a reliable, cost-effective, and easy-to-assemble door operator that efficiently converts manual actuation into door closure, with flexible mounting options and reduced complexity in production.
Implementation Method 1
an energy accumulator, particularly a compression spring, is arranged in the first cylinder housing. The energy accumulator cooperates with the piston.
Implementation Method 2
The piston and the driven shaft cooperate for mutual conversion between a linear movement of the piston and a rotational movement of the driven shaft.
Data Source
AI summary
A door operator includes a base plate with a receiving profile, a shaft housing inserted into the receiving profile, a first cylinder housing inserted into the receiving profile, a driven shaft rotatably bearing-mounted in the shaft housing, and a piston which is linearly movably guided in the first cylinder housing. The piston and the driven shaft cooperate for mutual conversion between a linear movement of the piston and a rotational movement of the driven shaft, and an energy accumulator is arranged in the first cylinder housing and cooperates with the piston.