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CONTEXT
Request:
A client was concerned that someone could open the cable cover and tamper internal cables.
Design Goal:
Develop a security solution that prevents the cable cover from being opened by bare hand.
Vendor's Proposal:
Add a screw hole at the bottom of the cable cover so a screwdriver is required for access.
Problems:
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Requires tooling change.
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Raises production cost.
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Affects all units for a single client.
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Visually intrusive.
Existing Mechanism
The cable cover opens though:
Slide Down → Lift Open
MOCK-UP
Finding an Attachment Point
I found an existing screw hole that:
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An add-on mechanism can attach to.
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Reachable by screwdriver.
Quick Low-Cost Exploration
I used folded paper to represent a thick sheet-metal bracket, attaching to the existing screw hole.
A Blocking Mechanism
If the blocking bracket is wider than the slide gap, the cover cannot be lifted.
Takeaway
Though this mechanism is simple and effective, it leaves no room for cables.
？
CONSTRAINTS TO SOLUTION
Identifying a New Attachment Point
The only available option left is the screw hole blocked by the cable cover.
Challenge:
The screw hole is unreachable by screwdriver.
？
Solution:
The Extending Piece:
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Extends screw access outward.
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Create new reachable screw position.
The Blocking Bracket:
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Mounted on extending piece.
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Physically blocks lift motion.
Step 1: Extending Piece
Step 2: Blocking Bracket
Validated Criteria:
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Cable clearance maintained.
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Screwdriver access enabled.
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No bare hand opening.
Business Impact:
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Manufacturing cost reduced — no tooling change.
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Optional add-on feature.
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Simplified manufacturing to save time & effort.
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Minimal visual exposure.
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Improved security.
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