Double security locking system - Design process

   It takes more than 10 times to complete the new folding system,  

   New structures often indicates that we are constantly making improvements.

   This is a classic folding mechanism (of course, the folding mechanism we used  is our own patent). Many vehicles are using this mechanism, especially ETWOW, who were the earliest adopters. Our mechanism has been provided to Swiss MICRO for use since 2019.

However, due to the emergence of the EN17128 regulation, this mechanism does not comply with the new regulations. Therefore, we must add a second safety lock to prevent the shaft from accidentally sliding out of the slot. As a result, we carried out a series of designs and finally came up with a solution. 

Let's take a look at the entire design process.

Solution 1: The sample can successfully perform its function.

On the original folding footrest, an additional mechanism is added externally to prevent the footrest from rotating. After design and verification, the solution is feasible, but its drawbacks are quite obvious. Therefore, the customer, Micro, who is not satisfied, so we need to continue to think of new solutions.

Those who are interested can watch the test video through the link below: 

Solution Two: The sample can successfully perform its function.

After internal discussion, we have decided to set up a physical barrier that cannot be bypassed by a single operation on the "exit" path of the original card slot. Since the shaft is made of iron, after manually opening the second lock, the automatic locking action of the second lock can be completed by utilizing the magnetic force of a magnet.

During the test, a problem was discovered. After folding, due to magnetic force, the locking piece would automatically unlock. It needed to be manually re-opened. After evaluation, this solution was found to be not very stable, so a new solution needs to be considered.

Those who are interested can watch the test video through the link below: 

SolutionThree: The sample can successfully perform its function. 

Based on Option Two, we have eliminated the magnetic solution. To prevent the automatic repositioning of the protective lock after folding, a telescopic mechanism (blue) has been designed internally. The operation steps are as follows: After manually opening to the designated position, the protective lock will stop at a certain position. When the shaft rises, it will touch the finger-like component, causing the protective lock to automatically leave the original locking point. During the unfolding process, it will automatically lock.

After verification, the plan was found feasible. However, after internal communication and discussion, it was considered unstable. Therefore, new plans need to be thought of.

Those who are interested can watch the test video through the link below: 

Solution 4:  The sample failed to achieve the intended function.

As the client requested that the protective mechanism be placed inside and not exposed externally, we had to design the structure within a very limited space. 

During the design process, we only considered the feasibility of the mechanism's structural principle, so many components were only 1-2mm thick. As a result, some issues were discovered during the sample assembly stage, and the second protective lock could not be successfully combined. 

Therefore, we need to continue to explore new solutions

Those who are interested can watch the test video through the link below: 

Solution 5: Succeed, we make it!

After trying out multiple plans, we changed the design direction and plan. Eventually, after repeated improvements and sample tests, the PHSCOO team confirmed the final double-lock protection mechanism.

We added a safety mechanism that restricts the sliding direction of the locking pin inside, and this component now has an automatic locking protection function. Only when the double-lock activation pedal is manually pressed to the designated position and held down continuously can the locking pin slide upwards; if it is stopped halfway or released, the protection mechanism will automatically lock and activate the function that restricts the sliding of the locking pin. 

This structure is simple, efficient and stable, adding a double-lock protection mechanism while greatly enhancing the user experience.

Those who are interested can watch the test video through the link below: 

 Enjoy every success in the process of design --PHSCOO