Electrical Subplate Channel Layout for Precise Device Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical devices often suffer from misalignment issues during assembly, leading to mechanical problems and inefficient installation processes, as existing methods require disassembly and blind adjustments, which can be time-consuming and result in poor performance, especially affecting ambient light sensors and guides.
Innovation Solution
The proposed solution involves a subplate with a channel that exposes screw holes, allowing for alignment adjustments without disassembly, using a screwdriver to tension screws and insert spacers for precise positioning, ensuring accurate alignment and reducing mechanical issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional assembly methods are used, then device components can be assembled, but misalignment occurs requiring disassembly and blind adjustments
Solution Approach 1:
The subplate is designed with pre-formed channels and opening patterns that guide screw placement and component alignment before final assembly. The channels are pre-positioned to expose specific screw holes at predetermined locations, eliminating the need for blind adjustments and ensuring accurate alignment from the outset.
Solution Approach 2:
The subplate acts as an intermediary component between the mounting surface and the electrical device components. It provides a standardized interface with pre-defined channel patterns that mediate the alignment between different components, ensuring precise positioning without requiring direct alignment between all components.
2Stability of the object's composition
If components are tightly assembled, then structural stability is achieved, but alignment adjustments become difficult
Solution Approach 1:
The channel design allows for dynamic adjustment during assembly. The channels are sized and shaped to permit insertion and adjustment of screws and spacers, providing flexibility during the assembly process. Once assembled, the structure achieves stability through the tightened screws while retaining the ability to make adjustments by loosening and repositioning components through the same channels.
Solution Approach 2:
The assembly is segmented into adjustable components (screws, spacers, subplate) that can be independently positioned and secured. This segmentation allows for iterative adjustment of individual elements through the channels while maintaining overall structural integrity, enabling fine-tuning of alignment without compromising stability.
3Productivity
If blind adjustments are made without visual access, then assembly can proceed, but alignment precision deteriorates
Solution Approach 1:
The subplate with its channel pattern serves as a visual intermediary that guides screw insertion and component positioning. The channels provide visible pathways that indicate where screws should be placed and how components should be aligned, eliminating blind adjustments while maintaining efficient assembly flow.
Solution Approach 2:
The channel openings and patterns on the subplate provide visual cues through their geometric patterns and openings. These visual features guide the assembler in positioning components correctly, with the channel shapes and positions serving as visual indicators for proper alignment without requiring additional markings or complex alignment tools.
Data Source
AI summary
Examples of electrical devices are described herein. In some examples, an electrical device includes a yoke plate including a first screw hole and a second screw hole. The electrical device includes a base including a third screw hole disposed to permit passage of a first screw through the third screw hole and the first screw hole. The electrical device includes a subplate including a fourth screw hole disposed to permit a second screw to attach the subplate to the yoke plate through the fourth screw hole and the second screw hole. The subplate includes a channel to expose the third screw hole to a facial side of the subplate.