A Project On

NEW PRODUCT DEVELOPMENT

5 SECURITY STRENGTHS

Godrej Security Strength – 1 Basic Security

Godrej Security Strength – 2 Ultra Security

Godrej Security Strength – 3 EXS Security

Godrej Security Strength – 4 Elite Security

Godrej Security Strength – 5 Advanced Electronic Security

1. LEVER TECHNOLOGY: Uses levers to restrict movement

of the bolt within the lock.

Number of levers usually an odd number for a

lock that opens from both sides.

Uses bitted keys made with the help of a code

system.

Code is usually translated from a key code chart or bitting system and input into the machine.

VARIOUS TECHNOLOGIES IN LOCKS

LEVERS

BOLT

BOLT SQUARE PIN

2. PIN CYLINDER TECHNOLOGY (ULTRA TECHNOLOGY): Uses pins of varying lengths to prevent the lock from opening

without the correct key.

Consists of a cylinder which must rotate

for the lock to open.

Cam/ bolt moving arrangement at the end of the

cylinder.

Each operating pin has a corresponding set of

spring loaded driving pins.

Inserting the correct key causes the pins to align along the “line of shear”.

VARIOUS TECHNOLOGIES IN LOCKS (Continued..)

3. EXS TECHNOLOGY: An improvement over ultra technology.

12 to 16 pins precisely positioned at special

angles.

EXS keys are manufactured by a profile milling.

Dimple depths in EXS keys are cut in the form of a

continuous surface.

Keys are impossible to duplicate

VARIOUS TECHNOLOGIES IN LOCKS (Continued..)

INTRODUCTION TO THE EXISTING BHANDAR LOCK

BASE PLATE COVER PLATE PRIMARY BOLT

SECONDARY BOLT LINK LEVERS

SLOTS

FULLY ASSEMBLED BHANDAR LOCK

WORKING OF THE EXISTING BHANDAR LOCK

Lever Technology is out-dated. Increased security desired.

Lock upgraded from Lever Technology to EXS Technology.

NEED FOR THE PROJECT AND SOLUTION

Study of existing Bhandar Lock.

Study of 2D Blueprints of current Bhandar Lock.

Work out Preliminary Design

Prepare 2D drawings of modified components

Prepare 3D Assembly of new design to detect flaws, if any.

Manufacture the lock in R&D

Assembly of the Lock.

Make any necessary corrections in the design

Manufacture and assemble according to new specifications.

STEPS FOLLOWED IN DESIGN OF THE EXS BHANDAR LOCK

CONCEPT DESIGN (EXS BHANDAR LOCK)

STAGE I :

STAGE II

STAGE III

STAGE IV

COMPONENTS OF THE NEW EXS BHANDAR LOCK

Primary Bolt

Secondary Bolt

Cylinder Cylinder Housing

Link

Cam

Cartridge Housing

Provisions for cartridge housing

Provision for cam

Bolt pin hole shifted

Design Trial I

Design Trial II

Initial resting position for spring

Final resting position of spring (Trial II)

Provisions for cartridge

PROTOTYPING – EXS BHANDAR LOCK

1. Spring wrongly made. Making corrections to spring futile. Solution – Spring used as it is and shifted to new position 2. Cam design faulty. Solution – Minor correction to cam design 3. Spacers needed for link and primary bolt Solution – Spacers provided. 4. Cam not fitting onto the surface of the cylinder. Solution – Inner circumference of the cam was filed. 5. Cartridge assembly with sleeve not fitting into cartridge housing. Solution – Inner surface of cartridge housing filed.

THE SAFE DEPOSIT LOCK RENTER PERSONAL LOCK

RENTER & CUSTODIAN LOCK

2D BLUEPRINTS OF THE NEW SAFE DEPOSIT LOCK

Base Plates Cover Plates

Bolts

• Modifications were made to the existing blueprints of the safe deposit lock.

• Provisions were made on the base and cover plates to accommodate the EXS mechanism.

• Bolts modified to facilitate the usage and functioning of the bolt catch spring.

Bolt Catch Spring

3D MODELLING

Software used: Creo Parametric 2.0

Problems Encountered During Prototyping:

The following problems were encountered while preparing the prototypes of the Safe Deposit Locks:

1. In the new design, some holes from the existing base plate were shifted from their initial positions. These new positions partially overlapped with the old ones.

2. The bolt was found to interfere with the base plate.

3. The bolt catch spring was found to be ineffective and did not provide the necessary feel during the locking and unlocking of the lock.

4. The custodian bolt was observed to be very tight while operating the lock.

PROTOTYPING – SAFE DEPOSIT LOCK

Renter Personal Lock

Renter(EXS) and Custodian (Lever)

Renter(EXS) and Custodian(EXS)

Brass(for EXS keys, cylinder, Mazak(Cartridge Housing):

cylinder housing): - Used for complicated

- High machinability geometries due to its high

- High Tensile Strength castability. Properties make it

- Corrosion resistant. suitable for hot chamber die casting.

- Low coefficient of friction - Can take all surface finishes.

- Recyclable - Readily machined.

CRCA Steel(Base & Cover Plate) Nickel Silver(Operating Pins):

- Used for lock bodies due to its - Consists of 60% copper, 20% nickel

high hardness and strength. and 20% zinc.

- High hardness and corrosion

resistance.

MATERIALS USED

The cost of both locks has increased in the process but it is well worth it considering the increased security at the customer’s disposal.

Reusing the existing framework with minimal changes is possible for both locks.

EXS technology was successfully incorporated into both locks.

CONCLUSION

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