Automotive Switch Display Section Positioning via Laser Ablation

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Solution Overview

Problem

Conventional steering switches for automobiles face issues with positional deviation of display sections due to measurement dispersion and wobble during assembly, making the manufacturing process time-consuming and expensive.

Innovation Solution

The solution involves forming display sections on operating units after assembly, using a camera and laser beam system controlled by a circuit to ensure accurate positioning, eliminating the need for visual checks and reducing positional deviations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If display sections are formed on operating units before assembly using laser beam, then manufacturing precision is improved, but positional deviation occurs due to measurement dispersion and wobble during assembly

Engineering Contradiction:

Improvepositioning accuracy of display sectionsVSAvoidpositional deviation of display sections

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent inverts the conventional sequence by forming display sections on operating units AFTER assembly into the housing rather than before. This reversal eliminates the problem of positional deviation during assembly, as the operating units are already fixed in their final positions when the display sections are created using laser beam processing.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent performs preliminary assembly of operating units into housing with through holes before forming the display sections. This preliminary positioning ensures that the operating units are securely held in their correct positions, eliminating measurement dispersion and wobble that would otherwise occur during subsequent handling and assembly steps.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If visual check is performed on display marks during assembly, then manufacturing precision is improved, but productivity deteriorates due to time-consuming inspection

Engineering Contradiction:

Improveaccuracy of display section positioningVSAvoidassembly speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent makes the system self-checking by forming display sections that are inherently visible and self-identifying. The translucent and non-translucent sections create naturally visible display areas that eliminate the need for separate visual inspection steps, as the correct positioning is self-evident from the appearance of the display sections themselves.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual visual inspection with automated laser beam processing. The laser system automatically forms display sections based on pre-stored position data, substituting human visual checks with automated optical processing that is both more precise and faster.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If operating units are assembled with display sections already formed, then ease of manufacture is improved, but positional deviation increases due to measurement dispersion

Engineering Contradiction:

Improvesimplicity of assembly processVSAvoidpositioning accuracy of display sections

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent inverts the conventional manufacturing sequence by assembling operating units into housing FIRST, then forming display sections on the assembled units. This reversal maintains ease of assembly while eliminating positional deviation, as the laser processing is performed on already-positioned units rather than attempting to position pre-marked units.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces manual measurement and positioning operations with automated laser beam processing guided by pre-stored position data. This substitution maintains manufacturing simplicity while achieving high precision, as the laser system automatically compensates for any variations in operating unit dimensions or positions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method results in switches with minimized positional deviation and simplified manufacturing, reducing errors and production time while maintaining ease of operation.

Implementation Method 1

shoot a laser beam onto the top face of the operating unit to remove a non-translucent section covering the surface of a translucent section

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS7578050B2Switch and method of manufacturing the same

Publication Date: 2009.08.25 PANASONIC AUTOMOTIVE SYST CO LTD

AI summary

A switch to be used mainly for controlling a variety of electronic devices in automobiles, and a method of manufacturing the same switch are disclosed for providing a switch free from positional deviation in its display section and easy to manufacture. Operating units having no display sections are mounted to a housing, then the shapes of each one of the operating units are recognized by a control circuit. An upper jig and a lower jig are moved for a laser beam device to remove a non-translucent section and expose parts of a translucent section, thereby forming the display sections. This structure allows eliminating positional deviation of the display sections and also requiring no visual checks done for confirming the display sections in manufacturing.