Switch actuator adapter

Abstract

The invention relates to a switch actuator adapter. The switch assembly is used to reform a non-contact switch into a contact-triggered switch such that an internal electrical state of the non-contact switch can be triggered by mechanical contact with an object or surface. The switch assembly may include an adapter body coupled to the contactless switch and an actuation body coupled to the adapter body. The actuation body is movable relative to the adapter body to selectively position a target supported by the actuation body within a sensing region of the contactless switch. The actuation body may be moved by an external object in contact with a portion of the actuation body.

Description

[0001] This application is a divisional application of the invention patent application titled "Switch Actuator Adapter", with an application date of March 23, 2022, and an application number of 202210290301.7.

[0002] Cross - reference to related patents

[0003] This application claims priority to and incorporates by reference in its entirety U.S. Patent Application No. 17 / 210,203, titled "Switch Actuator Adapter", filed on March 23, 2021. Technical field

[0004] The present invention relates to a switch actuator adapter. Background art

[0005] Contact switches typically rely on contact between a target (e.g., a moving surface) and another component to provide the force and displacement required to cause the contact switch to change state. Non - contact switches typically change state based on the proximity of another component to the switch without the need for mechanical contact. Summary of the invention

[0006] According to one aspect of the present disclosure, a switch assembly for detecting a system state is provided. The switch assembly includes an enclosed housing that surrounds a magnetic assembly. The magnetic assembly is configured to be selectively activated to move the switch assembly between a first state and a second state. The switch assembly further includes an adapter body fixed to the enclosed housing outside the enclosed housing and an actuator body movably supported by the adapter body, the actuator body supporting a target outside the enclosed housing. The target is at least one of a magnetic target or an iron - containing target. The actuator body is movable relative to the adapter body and the enclosed housing between a first orientation and a second orientation to move the target between a first position in which the target activates the magnetic assembly and a second position in which the target does not activate the magnetic assembly.

[0007] Some aspects provide an adapter system for a switch assembly to convert the switch assembly from a non - contact switch assembly to a contact switch assembly. The adapter system includes an adapter body, an actuator body, and a target, the adapter body configured to be fixed to an enclosed housing of the switch assembly outside the enclosed housing, the actuator body connected to and supported by the adapter body, the target connected to the actuator body and configured to be supported outside the enclosed housing via the adapter body by the actuator body. The actuator body is movable relative to the adapter body between a first orientation and a second orientation to move the target between a first position in which the target is oriented to activate the switch assembly from outside the enclosed housing and a second position in which the target is oriented not to activate the switch assembly.

[0008] Some aspects provide a method of converting a switch assembly from a non - contact switch assembly to a contact switch assembly to detect an event. The method includes fixing an adapter body to an outer surface of an enclosed housing of the switch assembly, and an actuator body is connected to the adapter body such that a target connected to the actuator body is supported by the adapter body and the actuator body outside the enclosed housing. The method further includes setting the actuator body to move from a first orientation to a second orientation relative to the adapter body when the event occurs, thereby moving the target from a first position to a second position, and the target is configured to activate the switch assembly from outside the enclosed housing when oriented in at least one of the first or second positions. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The drawings incorporated herein and forming a part of this specification illustrate embodiments of the invention and, together with the description, serve to explain the principles of the embodiments of the invention:

[0010] Figure 1 is a schematic diagram of a switch assembly for converting a non - contact switch to a contact switch.

[0011] Figure 2 is a perspective view of a switch assembly including a non - contact switch that is converted to be used as a contact switch with a lever - arm actuator body.

[0012] Figure 3 is Figure 2 an exploded view of the switch assembly.

[0013] Figure 4 is Figure 2 a cross - sectional view of the switch assembly in a first state.

[0014] Figure 5 is Figure 2 a cross - sectional view of the switch assembly in a second state.

[0015] Figure 6 is an exploded view of a switch assembly including a non - contact switch that is converted to be used as a contact switch with a button actuator body.

[0016] Figure 7 is Figure 6 a cross - sectional view of the switch assembly in a first state.

[0017] Figure 8 is Figure 6 a cross - sectional view of the switch assembly in a second state.

[0018] Figure 9Is an exploded view of a switch assembly including a non-contact switch having a square profile.

[0019] Figure 10 Is a schematic diagram of a switch assembly including a plurality of non-contact switches.

[0020] Figure 11 Is a schematic diagram of a switch assembly including a plurality of non-contact switches and a plurality of targets.

[0021] Figure 12 Is a schematic diagram of a switch assembly that includes a plurality of non-contact switches and a target configured to selectively activate one or more of the plurality of non-contact switches. Detailed Description

[0022] The following discussion is provided to enable a person skilled in the art to make and use embodiments of the present invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the general principles herein can be applied to other embodiments and applications without departing from the embodiments of the present invention. Thus, the embodiments of the present invention are not intended to be limited to the embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description will be read with reference to the accompanying drawings, in which like elements in different drawings have the same reference numerals. The figures, which are not necessarily drawn to scale, depict selected embodiments and are not intended to limit the scope of the embodiments of the present invention. Skilled artisans will recognize that the examples provided herein have many useful alternatives and fall within the scope of the embodiments of the present invention.

[0023] Before explaining in detail any embodiments of the present invention, it is to be understood that the application of the present invention is not limited to the details of construction and component arrangement set forth in the following description or shown in the drawings. The present invention is capable of other embodiments and of being practiced or carried out in various ways. Further, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. For example, as used herein, "including", "comprising", or "having" and their variants are intended to cover the items listed thereafter and their equivalents as well as additional items.

[0024] As used herein, unless otherwise stated or limited, the terms "mounted", "connected", "supported", "fixed", and "coupled" and their variants are used broadly when referring to physical connections and include direct and indirect mounting, connecting, supporting, and coupling. Further, unless otherwise stated or limited, "connected", "attached", or "coupled" is not limited to physical or mechanical connection, attachment, or coupling.

[0025] As described above, a contact switch (e.g., a limit switch) has traditionally relied on contact with a target (e.g., a movable surface) to provide the force and displacement required to cause the contact switch to change state. Typically, a conventional contact switch has an entry point through which a portion of the switch extends to change the state of the switch based on mechanical contact with another body external to the switch (e.g., a system body monitored by the switch). Thus, in order to provide a sealed enclosure for a contact switch, a movable seal typically must be provided, which can degrade and fail over time.

[0026] In contrast, a non-contact switch does not require contact with a target (e.g., a magnet or ferromagnetic material) to cause the non-contact switch to change state. Accordingly, a change in the state of a system monitored by a non-contact switch can cause a corresponding change in the state of the non-contact switch without the need for an entry point into the switch. Thus, for example, a non-contact switch may be particularly advantageous for an environment with a noxious gas, which preferably is not exposed to electronic devices or other potential spark points. However, since a non-contact switch may rely on a change in a non-mechanical field to cause a change in the state of the switch, the range of a non-contact switch may sometimes be smaller. Similarly, the area in which a non-contact switch can detect a change in the state of a monitored system may sometimes be smaller.

[0027] In view of the foregoing, it may be useful to provide improved switches and related systems and methods that can combine the advantages of non-contact and contact switches, including in new devices and for retrofitting existing devices. As will be described herein, the present disclosure provides systems and methods for adapting a non-contact switch to a mechanically actuated switch such that the non-contact switch can be triggered (i.e., the internal electrical state of the non-contact switch can be changed) by mechanical contact with an external object or surface.

[0028] In some embodiments, an adapter body can be provided that is configured to be secured to the housing of a non-contact switch. For example, an adapter body that supports an actuation body can be configured to be threadedly or otherwise mechanically attached to the housing of the non-contact switch (e.g., strapped thereto) without any portion of the adapter body or the actuation body entering through the wall of the non-contact switch housing. The actuation body, which can be formed as a lever, button, or according to other known types of mechanically movable interfaces, can support a target that is configured to trigger the non-contact switch based on the spatial orientation of the actuation body relative to the adapter body without entering the housing of the non-contact switch. Thus, for example, mechanical contact or other physical interaction with the actuation body that is entirely external to the housing of the non-contact switch can cause the target to move to trigger (or not trigger) the non-contact switch.

[0029] Figure 1FIG. illustrates an exemplary schematic diagram of a switch assembly 10 for detecting a system state in accordance with some embodiments of the present disclosure. In the illustrated embodiment, the switch assembly 10 includes a non-contact switch 12, an adapter body 14, and an actuator body 16. According to some embodiments, the actuator body 16 can be configured as a lever arm, button, latch, rod, link, roller, or other mechanical device that is movable relative to the adapter body 14. According to some embodiments, a contact roller ( Figure 1 not shown in FIG.) can be disposed on the actuator body 16 (e.g., at one end of the lever arm or button) and can provide a useful contact surface with the system to be monitored.

[0030] Moreover, the actuator body 16 includes a target 18 configured to trigger the non-contact switch 12. In some embodiments, the target 18 can be at least one of a magnetic target or an iron-containing target, but other configurations are also possible. Generally, the switch assembly 10 can be configured to be selectively actuated between a first state and a second state (or others) based on the non-contact switch 12 sensing (or not sensing) the target 18 within the sensing region 20. In the illustrated example, the sensing region 20 is shown as having a generally circular profile. However, different configurations of the sensing region are possible, depending on the specific configuration of the non-contact switch 12.

[0031] In different embodiments, different specific configurations of the non-contact switch 12 are possible, depending on the sensing and environmental constraints of a particular installation. For example, according to some embodiments, the non-contact switch 12 can be a magnetic switch or other type of proximity sensor, or other known types of switches that can be triggered by a corresponding target without contact with an external body. The internal configuration of the non-contact switch 12 relative to the system controlled by the switch 12 can also vary according to the needs of a particular installation. For example, according to some embodiments, the non-contact switch 12 can include a circuit for a single-pole double-throw switch (“SPDT”) (e.g., as shown in partial circuit 12d), a circuit for a double-pole double-throw (“DPDT”) switch (e.g., as shown in partial circuit 12e), a circuit for a single-pole single-throw (“SPST”) switch (e.g., as shown in partial circuits 12a, 12b), or a circuit for a double-pole single-throw (“DPST”) switch (e.g., as shown in partial circuit 12c). In some cases, the non-contact switch 12 can be configured as a “passive” switch. That is, the non-contact switch 12 can operate without consuming power. In some embodiments, the switch can additionally or alternatively include a circuit or other device for any kind of known switch, including a double-through double-break switch, a magnetic or inductive switch (e.g., a reed switch), a capacitive switch, or a mechanical switch.

[0032] To allow the target 18 to trigger the non-contact switch 12, the non-contact switch 12 and the actuation body 16 can be coupled to the adapter body 14. In some cases, the actuation body 16 can be directly fixed to the non-contact switch 12, combining the actuation body 16 and the non-contact switch 12 into a single, connected, and co-movable system. Additionally, the actuation body 16 can be movably supported by the adapter body 14 such that the actuation body 16 can move between a first orientation and a second orientation relative to the adapter body 14 (as indicated by arrow 22, which generally represents any type of movement of the actuation body 16, including translation, rotation, or a combination of both). As will be described below, when the actuation body 16 moves to one of the first orientation or the second orientation, the target 18 can thereby be placed in a position within the sensing region 20 of the non-contact switch 12 to activate the non-contact switch to one of a first state or a second state. Additionally, depending on the desired application, another orientation of the actuation body 16 can place the target 18 outside the sensing region 20.

[0033] Now referring to Figure 2 and 3 , a first embodiment of the switch assembly 10 is shown. The switch assembly 10 includes an adapter body 14 that is directly fixed to the housing 24 of the non-contact switch 12. As will be further described with reference to Figure 4 and Figure 5 , the housing 24 is configured to encapsulate a magnetic component to trigger the non-contact switch 12 based on external conditions. In particular, as Figure 2 and 3 show, the housing 24 includes a circular housing profile (i.e., having a circular cross-section). In other embodiments, the housing 24 can include a square housing profile (see Figure 9 ). In the embodiment shown in Figure 2 and 3 , the housing 24 also includes a threaded portion 26 along at least a portion of the length of the housing 24. As shown in the embodiments of Figure 2 and 3 , the threaded portion 26 is disposed along the circular profile portion of the housing 24, near one end of the housing 24.

[0034] Still referring to Figure 2 and Figure 3 , in the illustrated embodiment, the switch assembly 10 includes a base 30 that includes a mounting plate 32 fixed to the housing 24. Generally, the base 30 can be configured to fix the switch assembly 10 to a surface to support the switch assembly 10 during activation / actuation. In particular, as Figure 2 and 3As shown, the base 30 includes a strap 34 connected to the mounting plate 32. As shown, the strap 34 is integrally formed with the mounting plate 32, but other configurations are possible, including configurations where the strap 34 (or other strap) is not associated with a separate mounting plate.

[0035] In Figure 2 and 3 embodiments, the strap 34 defines an opening 36 that extends through the strap 34. The opening 36 defines a shape corresponding to the profile of the housing 24 (e.g., a circular profile, etc.). The strap 34 also includes a threaded portion on the inner surface that is configured to threadedly engage a threaded portion 26 of the housing 24. The threaded engagement between the base 30 and the housing 24 of the non-contact switch 12 can provide precise positioning of the housing 24 relative to the base 30 in some cases, but other configurations are possible. Once installed in the system, this precise positioning can provide accurate adjustment of the switch assembly 10.

[0036] The mounting plate 32 can also include one or more fastener holes 38 that are configured to receive fasteners (not shown) therein. Fasteners (e.g., rivets, bolts, screws, etc.) can be used to secure the base 30 and thus the switch assembly 10 to a surface or system (e.g., the position of a door or latch) where state detection is desired. In other embodiments, other configurations are possible. Generally, any type of mounting system can be used to secure the non-contact switch for use in a particular location as part of the switch assembly according to the present disclosure.

[0037] As Figure 3 shown, the adapter body 14 is external to the housing 24 and can be coupled to the distal end 40 of the housing 24. In the illustrated embodiment, the adapter body 14 is configured as a cylindrical sleeve that includes means for coupling to the actuating body 16 and the housing 24. For example, the adapter body 14 can be fixed to the housing 24 at a portion where the housing 24 defines a circular profile. In Figure 2 and 3 the illustrated embodiments, in particular, the adapter body 14 can be threadedly engaged with the housing 24. For example, the adapter body 14 defines an annulus and includes a threaded inner surface 42. The threaded inner surface 42 can be configured to threadedly engage the threaded portion 26 of the housing 24. Thus, for example, the threaded inner surface 42 can provide precise positioning of the actuating body 16, including the target 18, relative to the housing 24. This precise position can provide accurate adjustment of the target 18 relative to the sensing region 20 of the non-contact switch 12 (see Figure 1 ) including when used in combination with the engagement of the threaded strap with the base 30 as described above.

[0038] In Figure 2 and 3In the illustrated embodiment, the actuation body 16 includes a target 18, a lever arm 44, and a roller 48, but other configurations for supporting the target may be used in other cases. For Figure 2 and 3 the illustrated embodiment, the lever arm 44 is pivotally connected to the adapter body 14 to allow the target 18 to move between orientations. For example, the lever arm 44 may be pivotally coupled to the adapter body 14 by a pivot pin 46, and the target 18 may be coupled to the lever arm 44 near the pivot connection. Thus, when the lever arm 44 rotates, the positioning of the target 18 also changes. In the illustrated embodiment, the pivot pin 46 is configured to extend through the adapter body 14 and the lever arm 44 to pivotally secure the lever arm 44 to the adapter body 14, but a variety of other pivot arrangements are possible (e.g., having an integrally formed pivot pin, etc.).

[0039] In Figure 2 and 3 the illustrated embodiment, the roller 48 is coupled to the distal end 50 of the lever arm 44. Thus, the roller 48 can be easily positioned to engage the surface of the system to be monitored at the maximum distance provided by the lever arm 44 to allow actuation of the lever arm 44. In other embodiments, the roller may be positioned or configured differently, and some embodiments may not use a roller for this purpose.

[0040] Now referring to Figure 4 and 5 , a cross-section of the switch assembly 10 of Figure 2 and 3 is shown. As illustrated, in this embodiment, the non-contact switch 12 includes a magnetic assembly 52 enclosed within a housing 24. The magnetic assembly 52 is configured to be selectively activated to move the switch assembly between a first state ( Figure 4 ) and a second state ( Figure 5 ), but other internal switch configurations are possible as generally discussed above.

[0041] As Figure 4 and 5 shown, the lever arm 44 of the actuation body 16 can pivot between a first orientation ( Figure 4 ) and a second orientation ( Figure 5 ) relative to the adapter body 14 and the enclosed housing 24 to move the target 18 between a first position and a second position, where at the first position, the target 18 activates the magnetic assembly, and at the second position, the target 18 does not activate the magnetic assembly. For example, when the switch assembly 10 is in Figure 4In the case of the first state shown, the lever arm 44 can be positioned in a first orientation to position the target 18 in a first position (e.g., within the sensing region of the non-contact switch 12). When the target 18 is within the sensing region, the magnetic assembly 52 is activated by the magnet 54 included in the magnetic assembly 52 and moves within the housing 24 due to the magnetic attraction between the magnet 54 and the target 18.

[0042] Continuing to refer to Figure 4 and 5 , when there is contact between an external object (e.g., the surface of a moving object) and a portion of the actuating body 16 (e.g., the lever arm 44 or the roller 48), the switch assembly 10 can transition from the first state ( Figure 4 ) to the second state ( Figure 5 ). Contact from the external object can cause the actuating body 16 to move from a first orientation ( Figure 4 ) towards a second orientation ( Figure 5 ) relative to the adapter body 14. When the switch assembly 10 is in the second state ( Figure 5 ), the lever arm 44 pivots to a second orientation such that the target 18 is in a second position (e.g., positioned away from the sensing region of the non-contact switch 12). As the target 18 is positioned away from the sensing region of the non-contact switch 12, the magnet 54 in the magnetic assembly 52 transitions to a non-activated state (e.g., the target 18 does not activate the magnetic assembly 52).

[0043] In the illustrated embodiment, the magnet 54 of the magnetic assembly moves axially within the housing 24 according to the magnetic attraction between the target 18 and the magnet 54 to selectively activate the non-contact switch 12. In other embodiments, non-axial movement of the magnetic assembly is possible. Additionally, in some embodiments, the magnetic assembly of the non-contact switch can be repelled by the target and the response of the magnetic assembly to the position of the target changes accordingly.

[0044] In the illustrated embodiment, the outer housing 24 completely surrounds the magnetic assembly 52, and the adapter body 14, the actuator body 16, and the target 18 are all disposed entirely outside the enclosed outer housing 24. Thus, the outer housing 24 can be a sealed housing without an access point for activating the magnetic assembly 52. That is, the non-contact feature of the non-contact switch enables the magnetic assembly 52 to be selectively actuated without mechanical members or structures extending into the enclosed inner housing to move the magnet 54 of the magnetic assembly (or otherwise change the state of the non-contact switch 12). Accordingly, the magnetic assembly 52 is configured to be selectively actuated by the external target 18 without contact between the magnetic assembly 52 and the target 18, or even without contact between the outer housing 24 and the target 18. As described above, the absence of an access point can be beneficial, including to provide an outer housing 24 that can be configured as an explosion-proof housing. For example, the enclosed outer housing 24 provides a sealed inner chamber that prevents moisture, dust, dirt, corrosives, contaminants, or chemicals from reaching the magnetic assembly 52 or other internal components (e.g., circuits that may produce sparks).

[0045] According to some embodiments, a biasing element can be disposed between the adapter body 14 and the actuator body 16 such that the actuator body is biased in a particular direction. For example, a torsion spring (not shown), a helical spring (not shown), an elastomeric element (not shown), or other known biasing element can be disposed between Figure 4 and 5 the lever arm 44 and the adapter body 14 in the illustrated configuration (or in a similar location in other embodiments). Thus, the biasing element can be configured to bias the lever arm 44 into one of a first orientation or a second orientation. According to some embodiments, a spring effect can be provided by the magnetic repulsion or attraction between the target 18 and the magnet 54 within the magnetic assembly 52, rather than (or in addition to) by a separate spring or other biasing element. According to other embodiments, additional magnets can be disposed on the actuator body 16. The additional magnets can be configured to bias the actuator body 16 into one of a first orientation or a second orientation.

[0046] In some embodiments, the switch assembly 10 can generally be in one of a first state or a second state. For example, the arrangement of the biasing element can bias the lever arm 44 into Figure 4 and 5 one of the first orientation or the second orientation as shown. Additionally or alternatively, the target 18 can be repositioned on the lever arm 44 such that when the lever arm 44 is in the second orientation (i.e., the orientation as Figure 5 shown), the target 18 is aligned with the magnet 54 of the magnetic assembly 52. In this way, the arrangement of the target 18 on the lever arm 44 can determine whether the magnetic assembly is normally activated by the target 18. For example, in a configuration such as Figure 4In the illustrated embodiment, the switch assembly 10 is in a normal activated state. That is, the actuating body 16 can be biased to the illustrated orientation to align the target 18 with the magnet 54 of the magnetic assembly 52, thereby providing a switched state in which the magnetic assembly is normally activated.

[0047] Now referring to Figure 6 , a second embodiment of the switch assembly 10 is shown. In the following figures, like elements will be represented by like reference numerals. For example, Figure 6 the switch assembly 10 includes an adapter body 14 directly fixed to the housing 24 of the non-contact switch 12, and the actuating body 16 can be movably supported by the adapter body 14 such that the actuating body 16 can move between a first orientation and a second orientation relative to the adapter body 14. In the illustrated embodiment, the actuating body 16 includes a button 60 slidably disposed within the adapter body. The button 60 supports the target 18 which moves therewith. The switch assembly 10 also includes a biasing element 62 disposed between the housing 24 of the non-contact switch 12 and the button 60. In the illustrated embodiment, the biasing element 62 is a mechanical coil spring. According to other embodiments, the biasing element can be a magnet or a different type of spring. For example, an annular magnet can be coupled to the button that can oppose a magnet within the magnetic assembly, thereby providing a spring effect. As detailed below, the biasing element 62 can be configured to bias the actuating body 16 toward one of the first or second orientations.

[0048] In Figure 6 the illustrated embodiment, the adapter body 14 is configured as a cylindrical sleeve and includes means for connecting to the actuating body 16 and the housing 24. For example, the adapter body 14 can be threadedly engaged with the housing 24 via a threaded inner surface 42. The threaded inner surface 42 can be configured to threadedly engage a threaded portion 26 of the housing 24. The actuating body 16 can also define a bore 64 configured to slidably receive the button 60 therein.

[0049] Now referring to Figure 7 and 8 , a cross-section of the Figure 6 switch assembly 10 is shown. As shown, the non-contact switch 12 includes a magnetic assembly 52 enclosed within the housing 24. The magnetic assembly 52 is configured to be selectively activated to move the switch assembly 10 between a first state ( Figure 7 ) and a second state ( Figure 8 ). In the illustrated embodiment, the button 60 of the actuating body 16 can move axially between a first orientation ( Figure 7 ) and a second orientation ( Figure 8 ) relative to the adapter body 14 and the enclosing housing 24 to move the target 18 between a first position and a second position, respectively. For example, when the switch assembly 10 is in the first state ( Figure 7In the case of [[ID=]], the button 60 can be positioned in a first orientation to position the target 18 in a first position (e.g., outside the sensing region of the non-contact switch 12). When the target 18 is away from the sensing region, the magnetic assembly 52 is not activated (e.g., not in an activated state). When the switch assembly 10 is in the first state, the biasing element 62, which is a helical spring in this case, biases the button 60 of the actuating body 16 to the first orientation ( Figure 7 ), thereby positioning the target 18 supported by the actuating body 16 to the first position.

[0050] Then, upon contact between an external object (e.g., a surface) and a portion of the actuating body 16 (e.g., the button 60), the switch assembly 10 can transition from the first state to the second state. The contact from the external object can cause the actuating body 16 to move from the first orientation ( Figure 7 ), relative to the adapter body 14, towards the second orientation ( Figure 8 ). When the switch assembly 10 is in the second state ( Figure 8 ), the button 60 is translated to the second orientation such that the target 18 is in the second position (e.g., positioned within the sensing region of the non-contact switch 12). When the target 18 is located within the sensing region of the non-contact switch 12, the magnet 54 in the magnetic assembly 52 transitions to an activated state. In the illustrated embodiment, the magnet 54 of the magnetic assembly axially moves within the housing 24 according to the magnetic attraction between the target 18 and the magnet 54. This axial movement of the magnet 54 selectively activates the non-contact switch 12. (As also described above, other types of internal components for the non-contact switch are possible, including components that can be used with the button actuating body.)

[0051] As previously described, the switch assembly 10 can generally be in one of the first state or the second state. For example, the arrangement of the biasing element can bias the button 60 to one of the first orientation or the second orientation. For example, in Figure 7 the illustrated embodiment, the switch assembly 10 is in a normal non-activated state. That is, the actuating body 16 can be biased to the illustrated orientation, keeping the target 18 away from the magnet 54 of the magnetic assembly 52, thereby providing a switch state where the magnetic assembly is generally not activated. However, in other embodiments, the opposite configuration is also possible.

[0052] Now referring to Figure 9 , a third embodiment of the switch assembly 10 is shown. In the illustrated embodiment, the actuating body 16 is configured as the button 60, but other actuating body configurations are possible, including a lever arm (e.g., as previously described with respect to Figures 2 to 5 ). In Figure 9In the illustrated embodiment, the housing 24 includes a square (or other rectangular) housing profile. Accordingly, the adapter body 14 can be fixed to the housing 24 at a portion where the housing 24 defines a square profile. In the illustrated embodiment, the adapter body 14 can include an opening (not shown) configured to receive the housing 24 such that the adapter body 14 can be positioned around the housing 24. According to some embodiments, the adapter body 14 can provide an interference fit between the housing 24 and the adapter body 14 to fix the adapter body 14 to the housing 24. In other embodiments, the adapter body 14 can provide a sliding fit. In some embodiments, the adapter body 14 can be formed as or generally include a band (e.g., also as described above). In Figure 9 In the illustrated embodiment, the adapter body 14 includes an aperture 68 configured to align with the housing aperture 70 such that when the adapter body 14 is mounted to the housing 24, a fastener can be inserted through the aperture 68 and the housing aperture 70 to fix the adapter body 14 to the housing 24.

[0053] In Figure 9 the illustrated embodiment, the button 60 presents a rectangular profile and the aperture 64 in which the button 60 is slidably received in the actuation body 16 is also rectangular. In other embodiments, other shaped buttons are possible. Similarly, in some embodiments, the rectangular profile for the switch housing or for the adapter body can be implemented in combination with other types of actuation bodies, including levers (e.g., as described above).

[0054] As described above, some embodiments can include multiple switches (e.g., having corresponding multiple separate housings) that can be activated by one or more actuation bodies. For example, Figure 10 a switch assembly 100 is shown that includes a plurality of non-contact switches 12 coupled to and supported by the adapter body 14. The switch assembly 100 also includes an actuation body 16 that supports a target 18 and is movable relative to the adapter body 14, generally as indicated by the arrow 122. It should be understood that while the arrow 122 represents a pivoting or rotational movement, in some embodiments, the actuation body 16 can also (or alternatively) translate. Thus, the actuation body 16 can generally move relative to the adapter body 14 to selectively activate one or more of the non-contact switches 12, including activating them individually or jointly (in various combinations), depending on the configuration of the particular installation.

[0055] In some examples, including as Figure 10In the example shown, each of the plurality of non-contact switches 12 may encapsulate a magnetic component 52 configured to be selectively activated by a target 18. Accordingly, by means of an iron-containing or magnetic configuration for the target 18, the actuating body 16 may be moved relative to the plurality of non-contact switches 12 to selectively actuate one or more of the non-contact switches 12. For example, in the illustrated embodiment, when the actuating body 16 is moved, the switch assembly 100 may be configured to detect the target 18 at a plurality of different positions. In this way, a plurality of positions of the actuating body 16 may be determined based on which of the plurality of non-contact switches 12 is in an activated state, which may correspond to a plurality of positions of an external object in contact with the actuating body 16.

[0056] In some embodiments, a plurality of switches (e.g., having corresponding plurality of individual housings) may be configured to be activated by a plurality of targets (e.g., respectively) supported on one or more actuating bodies. For example, Figure 11 A switch assembly 200 including a plurality of non-contact switches 12 is shown, the plurality of non-contact switches 12 being coupled to and supported by an adapter body 14. In the illustrated embodiment, the adapter body 14 supports an actuating body 16 and the actuating body 16 supports a plurality of targets 18. Accordingly, movement or orientation of the actuating body 16 (e.g., as indicated by arrow 222) may cause the plurality of targets 18 to move together to selectively activate one or more of the plurality of non-contact switches 12. For example, as Figure 11 shown, the actuating body 16 may be moved relative to the adapter body 14 and the plurality of non-contact switches 12 (e.g., as indicated by arrow 222) to cause the targets 18 to move together, thereby selectively activating the magnetic components 52 enclosed within each of the plurality of non-contact switches 12. In some embodiments, the actuating body 16 may be formed by a plurality of individual moveable bodies, including for example Figure 11 as indicated by the dashed lines in. Accordingly, in some embodiments, movement of different specific components relative to a common adapter body 14 may selectively activate corresponding specific non-contact switches.

[0057] In some embodiments, a plurality of switches (e.g., having corresponding plurality of individual housings) may be configured to be activated by a single target supported on an actuating body. For example, Figure 12A switch assembly 300 is shown that includes a plurality of non-contact switches 12 that are coupled to and supported by an adapter body 14. In the illustrated embodiment, the adapter body 14 supports an actuator body 16 that includes a target 18 that is configured to simultaneously activate one or more of the plurality of non-contact switches 12. For example, the target 18 can be sized such that when the actuator body 16 moves within the sensing regions 20 of the plurality of non-contact switches 12, the target 18 can selectively and simultaneously activate a plurality (e.g., all) of the magnetic assemblies 52 enclosed within the non-contact switches 12.

[0058] As previously described herein, some of the disclosed switch assemblies can generally be used to adapt non-contact switches to mechanical trigger switches such that the internal electrical state of the non-contact switch can be triggered by an event (e.g., a proximity event) resulting in mechanical contact with an object or surface. Thus, for example, some embodiments can allow for the conversion of a non-contact switch to a contact switch assembly, or can allow a non-contact internal switch device (e.g., an internal switch circuit) to be adapted for contact-based triggering. Accordingly, the non-contact switches 12 (e.g., magnetic switches) previously described herein are configured to operate as switches that are triggered without mechanical contact, independent of the actuator body 16 or the adapter body 14, but can generally be adapted for contact-based operation in various embodiments. For example, a magnetic switch can operate alone as a proximity sensor and, using the systems and methods herein, can also be improved or adapted to operate as a contact switch (e.g., a limit switch). Similarly, in some embodiments, non-contact circuits or other components can be adapted to be used with non-modified contact sensors.

[0059] In some embodiments, methods embodying aspects of the present invention can be used to utilize, manufacture, or install the devices or systems disclosed herein. Accordingly, any description herein of a particular feature, capability, or intended purpose of a device or system is generally intended to include a disclosure of a method of using such device for its intended purpose, a method of achieving such capability in other ways, the related components for manufacturing such device or system (or the entire device or system), and a method of installing the disclosed (or otherwise known) components to support such purpose or capability. Similarly, unless otherwise stated or limited, any discussion herein of a method of manufacturing or using a particular device or system (including installing the device or system) is intended to inherently include a disclosure of the features used and the implementation of the functionality of such device or system as embodiments of the present invention.

[0060] In this regard, for example, some embodiments include methods of converting a switch assembly from a non-contact switch assembly to a contact switch assembly to detect an event. In the following description, reference will be made to Figure 1 . However, with reference to Figure 1, it should be understood that the following description generally also applies to the various other embodiments described herein.

[0061] Specifically referring to Figure 1 , the adapter body 14 can be fixed to the outside of the housing (such as housing 24) of an existing non-contact switch 12 that is desired to be converted to perform the function of a contact switch. The actuating body 16 can be connected to and supported by the adapter body 14 such that the target 18 connected to the actuating body 16 is supported by the adapter body 14 and the actuating body 16 outside the housing of the non-contact switch 12. The actuating body 16 can then be arranged to move relative to the adapter body 14 (and subsequently relative to the non-contact switch 12 itself). Upon occurrence of a proximity event, the actuating body 16 can move from a first orientation to a second orientation (e.g., by contact with an external object), thereby causing the target 18 to move from a first position to a second position. Thus, the target 18 can selectively activate the switch assembly 10 from outside the housing of the non-contact switch 12 based on the position of the actuating body 16 (e.g., according to whether it is aligned within the sensing area 20 of the non-contact switch 12). According to some embodiments, the housing 24 of the non-contact switch 12 can be inserted or mounted onto a base (e.g., Figure 2 base 30) to be fixed to a surface or system.

[0062] The foregoing description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein can be applied to other embodiments without departing from the spirit or scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for converting a switch assembly from a non - contact switch assembly to a contact switch assembly to detect an event, the method comprises: fixing an adapter body externally to a closed housing of the switch assembly, an actuating body being connected to the adapter body such that: a target connected to the actuating body is supported by the adapter body externally to the closed housing, the target being at least one of a magnetic target or an iron - containing target; and the actuating body is arranged to move from a first orientation to a second orientation relative to the adapter body upon the occurrence of an event, to activate the switch assembly by moving the target between a first position external to the closed housing and a second position external to the closed housing.

2. The method according to claim 1, wherein, the closed housing is a sealed housing having no entry point for activating a magnetic component within the closed housing; and wherein the actuating body is arranged to move between the first orientation and the second orientation without any part of the adapter body, the actuating body or the target extending into the interior of the closed housing.

3. The method according to claim 1, wherein, the actuating body is arranged to activate a plurality of switch assemblies from externally of respective closed housings of the plurality of switch assemblies.

4. The method according to claim 1, wherein, the actuating body is a lever arm pivotally fixed to the adapter body.

5. The method according to claim 1, wherein, fixing the adapter body to the closed housing comprises: thread - fixing the adapter body to the closed housing.

6. The method according to claim 1, wherein, fixing the adapter body to the closed housing comprises: inserting a strap of a base through the closed housing, the base being for use with the adapter body.

7. The method according to claim 1, wherein, the closed housing and a magnetic component within the closed housing are configured to operate as a magnetic switch independently of the adapter body and the actuating body.

8. The method according to claim 1, wherein, the switch assembly includes a biasing element configured to bias the actuating body towards one of the first orientation or the second orientation.

9. The method according to claim 1, wherein, the actuating body is a button.

10. The method according to claim 9, wherein, the button is biased towards the first orientation by one or more of the target or the biasing element.

11. A method for converting a switch assembly from a non - contact switch assembly to a contact switch assembly, the method comprises: fixing an adapter body to a sealed housing of a switch assembly, a magnetic component being enclosed within the sealed housing, the adapter body supporting an actuating body including a target configured to magnetically activate the magnetic component of the sealed housing; and selectively actuating the actuating body to move between a first orientation and a second orientation relative to the adapter body, the actuating body positioning the target in a first position in the first orientation so as not to activate the magnetic component, and The actuating body positions the target at a second position in the second orientation to activate the magnetic assembly.

12. The method according to claim 11, wherein, the target is outside the sealed housing in both the first position and the second position.

13. The method according to claim 12, wherein, the actuating body moves between the first orientation and the second orientation, and no part of the adapter body, the actuating body or the target extends into the interior of the sealed housing.

14. The method according to claim 11, wherein, fixing the adapter body to the sealed housing includes: threadedly fixing the adapter body to the sealed housing.

15. The method according to claim 11, wherein, fixing the adapter body to the sealed housing includes: inserting the sealed housing through a strap of a base, the base being for use with the adapter body.

16. The method according to claim 11, wherein, the switch assembly includes a biasing element configured to bias the actuating body toward one of the first orientation or the second orientation.

17. The method according to claim 11, wherein, the actuating body is a lever arm pivotally fixed to the adapter body.

18. The method according to claim 11, wherein, the actuating body is a button.

19. A method of using a switch assembly, the method comprising: selectively actuating an actuating body between a first orientation and a second orientation, the actuating body supporting a target and being movably supported by an adapter body, and the adapter body being fixed to a sealed housing that encloses a magnetic assembly without an access point for activating the magnetic assembly; when the actuating body is in the first orientation, the target is in a first position to deactivate the magnetic assembly of the sealed housing; and when the actuating body is in the second orientation, the target is in a second position to activate the magnetic assembly of the sealed housing.

20. The method according to claim 19, wherein, the actuating body moves between the first orientation and the second orientation, and no part of the adapter body, the actuating body or the target extends into the interior of the sealed housing.

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