Security Solution

Research

Our extensive research for ergonomic data, standard components, possible manufacturing processes and market competition involve prior art study, experimentation and brainstorming with a cross-functional team. A wide research was conducted all over the country to find the pain points in the existing rim lock category. The findings suggested that there is a wide scope of improvement in the overall feel and functioning of the lock. Hence, the most critical aspect of the brief was to design and develop a mechanism which would ease out the operation for the oldest member of the family.

Design Development

There are three major Variants, Dead bolt, Twin bolt & Tri bolt in the Ultra rim range. Also, all the three rim lock variants available in the market have no common design element. GLSS approached us for a facelift of the ultra rim locks range. The main aim of the project was to upgrade the current rim locks series in terms of usability, ergonomics and enhance its security features.

Engineering

Ultra XL rim locks have 3 major variants and other SKUs, depending upon the number of bolts and key cylinders it withholds. Part commonality grants a major advantage in this. Our engineers designed the parts such that most of them can be used without further processing in other variants of the lock also. Our expertise in manufacturing processes assisted us in ensuring value addition in design for mass production.

The main task was to re-iterate the profiles of the internal components to smoothen out their functioning. Along with the profiles of the internal components, the spring force was of uttermost significance. Our expertise in spring design enabled us to calculate the precise force required to smooth functioning of the respective cams. Efforts were made to achieve the smooth transitions of the mechanism and tactile feedback while operating the knob to aid the hassle-free user experience.

Prototyping

A mock-type was built to validate the results. The development of the mechanism was a continuous process of incremental improvements. Our prototyping team excels in most of the manual operations like hand forming, sculpting etc. Thus, fine modification in the existing components was possible. The refinements made in the lock's proto played an important roll in achieving the smooth transition and helped us in guiding the production process.

Also, they are well-versed with the advanced processes like 5-axis CNC machining and Rapid Prototyping. Hence, it can be implied that the development of a prototype or a new component is undoubtedly possible within no time.

Production

Our engineering team facilitated the production process and worked with the manufacturers to get the product as desired. The housing is made from a single piece of sheet metal to impart its seamless look and unparalleled strength. For this, the sheet metal piece is blanked to the right size and drawn. Several iterations were done to achieve the desired contour. Sheet metal forming process has been optimized for a good finish with fewer post-processes. The studs are welded using projection welding leave no witness mark on the aesthetic surface.

The main motive of the industrial design team was to establish the idea of ‘design family ’ where all the different variants of this rim lock category have a common design language. The most significant aspect of our industrial design was that the forms of the proposed family of locks were forming-friendly. Our previous experience and insights in sheet metal processes guided us to develop a superior form within the scope of the drawing process. Special attention was given to the fact that a lock can be fitted on the left-hand and right-hand doors, thus, making it a universal design.

Packaging

Structural packaging and product communication was a parallel activity. Our communication design team is proficient in comprehending all the features of the product and effectively communicating them.

Each variant of the lock was critically analyzed from a marketing perspective to create the best shelf impact. So also, the box was structurally engineered to withstand the load of the lock and to protect it from unintended abuse during handling and transportation. All this was achieved in stingy cost constraints.

Ultra XL+  

All variants