ATV Switch Actuator Housing Design for Rugged Use

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Solution Overview

Problem

Existing switch housings for ATV machines require multiple components to accommodate larger switch actuators, complicating assembly and robustness, especially in rugged environments.

Innovation Solution

A single-piece switch actuator design with a housing and insert formed by injection molding plastic or metal, featuring an opening with side slots for flanges to securely close the back of the housing, allowing for a robust and easy-to-assemble switch actuator device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple components are used to accommodate larger switch actuators, then the switch actuator can fit the housing opening, but the assembly becomes complex and less robust

Engineering Contradiction:

Improveswitch actuator size accommodationVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the switch actuator and housing into a single integrated component. The housing includes a recess that directly receives and accommodates the switch actuator, eliminating the need for separate adapter components. This integration reduces the number of parts while maintaining the ability to accommodate larger switch actuators through the designed recess geometry.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If multiple components are used for switch actuator housing, then larger actuators can be accommodated, but assembly becomes difficult and time-consuming

Engineering Contradiction:

Improveswitch actuator size accommodationVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The integrated housing design with built-in recess eliminates multiple assembly steps. The switch actuator is directly inserted into the recess of the single-piece housing, reducing assembly operations compared to fitting multiple separate components together.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple components are used to build the switch housing, then larger actuators can be fitted, but the construction becomes less robust for rugged environments

Engineering Contradiction:

Improveswitch actuator size accommodationVSAvoidrobustness in rugged environments

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The single-integrated housing design eliminates joints and interfaces between multiple components, creating a more robust structure. The recess is directly formed in the housing body, providing structural integrity and resistance to vibration and shock typical of rugged ATV environments.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP2156453B1ATV switch actuator and housing design

Publication Date: 2017.03.22 HONEYWELL INTERNATIONAL INC

AI summary

A switch activator device for ATVs and like vehicles operating in robust environments having a switch housing including an open back side and a front side having a central opening and at least one slots for receiving a switch actuator. At least one switch activator is mounted in the housing with a flange sized to engage the at least one slot in the housing. A central housing insert is put in the housing between the at least one activator to substantially close off the front side of the housing and provide mounting support to maintain the at least one actuator flange in the slot. Preferably the housing, actuators and insert are made by injection molding plastic.