Segmented Footrest Structure for Angled Shape Manufacturing
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Solution Overview
Problem
The manufacturing of footboards for saddle-ride type vehicles with an angled shape is challenging due to difficulty in dimension control of metal and elastic members, leading to large-scale facilities and complex mold requirements, making it hard to achieve both appearance quality and ease of manufacturing.
Innovation Solution
A footrest structure with a footboard configured in series, featuring a bent portion between two footrest portions, where the first and second footrest portions are made with elastic and metal members respectively, and the bent portion is made solely of elastic material, allowing for easier bending and reduced mold complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a footboard is made to be an angled shape with metal members for enhancing appearance quality, then the quality of appearance is improved, but the dimension control becomes difficult and the manufacturing facility scale becomes large
Solution Approach 1:
The footboard is segmented into three distinct portions: a first footrest portion, a bent portion, and a second footrest portion. The bent portion is further segmented to include recess portions that facilitate bending. This segmentation allows different portions to have different structural characteristics - the first and second footrest portions maintain rigid metal members for appearance, while the bent portion becomes flexible for easy angling without requiring complex dimension control across the entire structure.
Solution Approach 2:
The bent portion is given locally different properties from the rest of the footboard by removing metal members and creating recess portions. This local modification makes only the bent portion flexible and easy to shape, while the first and second footrest portions retain their rigid, appearance-enhancing metal construction. This resolves the contradiction by applying quality differentiation to specific locations rather than uniformly across the entire footboard.
2Shape
If a footboard is made to be an angled shape with metal members for enhancing appearance quality, then the quality of appearance is improved, but the manufacturing facility scale becomes large
Solution Approach 1:
By segmenting the footboard into portions with different structural characteristics, the manufacturing process can be simplified. The bent portion with recess portions can be formed using simpler, smaller-scale facilities compared to what would be required to form an entire angled footboard with uniform metal construction. This segmentation enables the use of more compact manufacturing equipment.
Solution Approach 2:
The local modification of the bent portion (removing metal members, adding recess portions) allows this specific area to be manufactured with simpler, smaller-scale facilities. The rest of the footboard can be produced separately or with different equipment, avoiding the need for large-scale facilities required to manufacture a complete angled metal footboard in one piece.
3Shape
If an integral joint of outer layer covers both footrest portions for angled shape, then the appearance quality is enhanced, but the bent portion becomes difficult to form
Solution Approach 1:
The footboard is segmented so that the bent portion is structurally separated from the first and second footrest portions. By removing metal members from the bent portion and creating recess portions, the bent area becomes independently formable. This segmentation allows the bent portion to be shaped separately without being constrained by an integral joint structure that would cover and complicate the formation of both footrest portions.
Solution Approach 2:
The bent portion is given locally different properties by excluding metal members and adding recess portions, making it specifically suited for easy bending. This local quality differentiation resolves the contradiction by making the bent portion easy to form while the first and second footrest portions maintain their rigid, appearance-enhancing metal construction with integral joints.
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 configuration enhances the appearance quality of the footboard while simplifying the manufacturing process by allowing the footboard to be easily bent into an angled shape, reducing mold size and complexity, and preventing floating issues through strategic recess and attaching boss placement.
Implementation Method 1
the bent portion (33) is configured with the elastic member (35) only... the bent portion configured with the elastic member only is bent easily
Data Source
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AI summary
[Problem] To enable a footboard being excellent in the quality of appearance to be manufactured easily. [Solution] In a footrest structure for a saddle-ride type vehicle, including a footboard 22 which is configured in series from a first footrest portion 31 to a second footrest portion 32 located behind the first footrest portion 31, a bent portion 33 is provided between the first footrest portion 31 and the second footrest portion 32, the first footrest portion 31 and the second footrest portion 32 are each configured with an elastic member 35 and a metal member 36, and the bent portion 33 is configured with the elastic member 35 only.