Sheet-Metal Positioning Structure for Rigid Precision Assembly
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Solution Overview
Problem
Conventional sheet-metal structures in image forming apparatuses face challenges in achieving accurate and rigid coupling between sheet-metal members, often requiring reinforcement and adjustment members, which can lead to inefficiencies and potential deformation.
Innovation Solution
A sheet-metal structure featuring a positioning mechanism with a swaged portion, an opening portion, and a restriction portion that allows the second sheet-metal member to bridge between first sheet-metal members, positioning them accurately and securely through deformation of the bent portion, eliminating the need for reinforcement and adjustment members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If reinforcement members and adjustment members are added to achieve accurate coupling, then the positioning precision and structural strength improve, but the device complexity and manufacturing cost increase
Solution Approach 1:
The positioning mechanism integrates multiple functions into a single structure: the positioning protrusion and positioning groove provide positioning, the swaged portion provides both positioning and clamping, and the bent portion serves as both a connector and a deformation-based fixing element. This merging eliminates the need for separate reinforcement members and adjustment members while maintaining positioning precision.
Solution Approach 2:
The invention utilizes deformation of the bent portion as a parameter change to achieve fixing. By controlling the deformation of the bent portion during assembly, the structure transitions from a loose state to a tightly fixed state, providing both positioning and securing functions without additional components.
2Stability of the object's composition
If conventional coupling methods are used, then the assembly process is simple, but the rigidity of coupling parts is insufficient and deformation occurs
Solution Approach 1:
The bent portion is designed with a curved geometry that allows it to deform and conform to the swaged portion during assembly. This curvature enables the bent portion to flex and lock into place, providing reliable fixing while maintaining the rigidity of the overall coupling structure.
Solution Approach 2:
The positioning mechanism incorporates dynamic elements: the swaged portion can elastically deform to accommodate the bent portion during assembly, and the bent portion itself deforms to achieve the fixed state. This dynamic behavior allows the structure to transition from assembly to a rigid, deformation-resistant state.
3Strength
If additional reinforcement members are installed, then the structural strength improves, but the assembly time and productivity decrease
Solution Approach 1:
The bent portion serves itself by deforming during assembly to create the fixed state. The deformation of the bent portion automatically provides both positioning and securing functions, eliminating the need for separate reinforcement members and reducing assembly steps, thereby improving productivity while maintaining structural strength.
4Manufacturing precision
If adjustment members are added for precise positioning, then the positioning accuracy improves, but the device complexity and number of components increase
Solution Approach 1:
The positioning protrusion and positioning groove are integrated directly into the first and second sheet metal members, respectively. This integration provides precise positioning without requiring separate adjustment members, reducing the number of components while maintaining positioning accuracy.
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 enhances the rigidity of the coupling parts, reduces the likelihood of deformation, and allows for precise positioning without additional components, improving the structural integrity and assembly efficiency of the image forming apparatus.
Implementation Method 1
the bent portion deforms in the direction toward the first sheet-metal member to make contact with the first sheet-metal member, thereby fixing together the first sheet-metal member and the bent portion
Data Source
AI summary
A sheet-metal structure includes a pair of first sheet-metal members, a second sheet-metal member, and a positioning mechanism. The second sheet-metal member has a flat main body portion and a pair of bent portions formed by substantially perpendicularly bending opposite end parts of the main body portion. The positioning mechanism has a swaged portion projecting inward from the inner surface of the first sheet-metal plate, an opening portion extending from the bent portion to the main body portion, and a restriction portion formed at the main body portion side end of the opening portion. The distance from the bent portion to the restriction portion is smaller than the projection height of the swaged portion. With the swaged portion in contact with the restriction portion, fixing together the first sheet-metal member and the bent portion at a fixing position away from the restriction portion across a predetermined distance.