Segmented Reinforcement Pillar Assembly for Machine Housing
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Solution Overview
Problem
The manufacturing of reinforcement pillars for machine housings is time-consuming and costly due to their complex structure, which also complicates servicing and increases overall production costs.
Innovation Solution
A reinforcement pillar assembly comprising a cover panel formed through thermoforming of a polymer material and a support pillar made of metallic material, with the support pillar attached to the cover panel using adhesive material and fasteners, reducing the complexity of the assembly and eliminating the need for high precision machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high precision machining (router machining, CNC machining, high precision milling) is used to manufacture reinforcement pillars, then manufacturing precision is improved, but manufacturing time and cost increase substantially
Solution Approach 1:
The reinforcement pillar is divided into multiple components: a base component and one or more cover components. Each component can be manufactured separately using simpler, less time-consuming processes, then assembled together to form the complete reinforcement pillar assembly, thereby reducing overall manufacturing time while maintaining precision through modular construction
Solution Approach 2:
The cover components are designed to fit over and surround the base component, creating a nested structure where the cover portion encapsulates the base portion. This nesting approach allows complex geometries to be achieved through layering simpler components rather than machining the entire complex shape in one piece
2Manufacturing precision
If high precision machining is used to manufacture reinforcement pillars, then manufacturing precision is improved, but manufacturing cost increases substantially
Solution Approach 1:
By segmenting the reinforcement pillar into base and cover components manufactured through different processes (injection molding for base, thermoforming for cover), the patent avoids the high cost of precision machining while achieving the required manufacturing precision through appropriate process selection for each component
Solution Approach 2:
The reinforcement pillar assembly combines different materials (metal or plastic for base, polymer sheet for cover) manufactured through different processes, allowing each material to be optimized for its specific function and manufactured cost-effectively
3Shape
If reinforcement pillars have a substantially complex structure, then aesthetic and functional requirements are met, but servicing becomes cumbersome
Solution Approach 1:
The complex structure is segmented into a base component and removable cover components. This segmentation allows the cover portions to be easily removed for access to internal components during servicing, while still providing the complex aesthetic and protective structure when assembled, thereby improving ease of repair without sacrificing structural complexity
Solution Approach 2:
The cover components can be extracted or removed from the base component during servicing operations, allowing technicians to access internal machine components without disassembling the entire reinforcement pillar, thus simplifying maintenance while maintaining the complex external structure
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 proposed solution significantly reduces the manufacturing time and cost of reinforcement pillar assemblies, simplifies servicing, and maintains the temperature of the machine housing during operation by allowing air flow between the housing and the pillar assembly.
Implementation Method 1
The cover panel is made by performing a thermoforming process on a sheet of a polymer material
Implementation Method 2
The support pillar is attached to the cover panel with an adhesive material and fasteners
Data Source
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AI summary
A reinforcement pillar assembly and a method for manufacturing such assembly for a machine are disclosed. The reinforcement pillar assembly includes a cover panel formed of a polymer material. The cover panel includes an outer surface and an inner surface adapted to face in a direction towards a wall of the machine housing. Further, the reinforcement pillar assembly includes at least one support pillar formed of a metallic material. The at least one support pillar is adapted to be coupled to the cover panel. The at least one support pillar includes a first planar extension and a second planar extension. The first planar extension is adapted to be coupled to the inner surface of the cover panel. The second planar extension is adapted to abut the wall of the machine housing. A gap is defined between the inner surface of the cover panel and the wall of the machine housing.