Cam Actuated Switch Module Eliminating Bridge Connections
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Solution Overview
Problem
Conventional cam-operated switches are complex, costly, and inefficient due to the use of multiple components and bridges, leading to increased power losses and larger size, which is not environmentally friendly for applications requiring continuous and uninterrupted electrical supply.
Innovation Solution
A cam actuated switch module composed of two identical semi-modules with identical casing halves and switches, eliminating the need for external bridges by directly connecting terminals, reducing material usage and heat losses, and using a rotatable cam for actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If bridges are used to connect terminals of switches, then electrical connection is achieved, but power losses increase due to increased electrical resistance
Solution Approach 1:
The patent removes the bridges (intermediate connection elements) from the system entirely. Instead of using bridges to connect terminals of different switches, the invention directly connects the terminals through the common shaft structure, eliminating the source of electrical resistance and power losses at the bridge-terminal interfaces.
Solution Approach 2:
The patent merges the functions of multiple components into a unified structure. The common shaft serves simultaneously as the mechanical actuation element for multiple switches and as the electrical connection path between terminals, eliminating the need for separate bridge components and reducing overall electrical resistance.
2Loss of energy
If bridges and screws are used for terminal connections, then electrical connection is established, but heat losses increase at the interface areas
Solution Approach 1:
The invention removes the screw-fastened bridge components that create hot spot interfaces. By eliminating these intermediate connection elements, the patent removes the primary sources of heat generation at connection interfaces, as there are no more bridge-terminal interfaces to generate Joule heating.
3Ease of manufacture
If multiple different components are used in cam switches, then switching function is achieved, but manufacturing cost increases
Solution Approach 1:
The common shaft serves multiple functions simultaneously: it acts as the mechanical actuator for multiple cam-operated switches, provides the structural framework for mounting switches and terminals, and serves as the electrical connection path between terminals. This multi-functionality reduces the total number of components needed and simplifies manufacturing.
Solution Approach 2:
The patent divides the switch assembly into modular units (individual switches mounted on the common shaft) that can be manufactured separately and then assembled. This segmentation allows for standardized production of individual switch modules, reducing overall manufacturing complexity and cost while maintaining functional performance.
4Volume of stationary object
If bridges are used to form common terminals, then electrical connection is achieved, but the size of the switch increases
Solution Approach 1:
The patent combines the electrical connection function with the mechanical support structure. The common shaft and mounting framework simultaneously provide structural support for multiple switches and serve as the electrical interconnection path, eliminating the need for separate bridge components and reducing overall device volume.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces manufacturing costs, minimizes power losses by up to 50%, enhances electrical endurance by 60%, and decreases the size of the switch, resulting in a more efficient and sustainable product with a longer lifespan.
Implementation Method 1
A rotatable cam is placed inside the casing and retained by (or assembled between) the two casing halves, and configured for selectively actuate (open and close) the first and second switches upon rotation of the cam
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The present invention refers to a cam actuated switch module and to its manufacturing method. The module is made up of two identical semi-modules attachable to each other, the semi-modules comprising two identical casing halves and two identical switches, respectively fitted inside the first and second casing halves. A rotatable cam is placed inside the casing and configured for selectively open and close the first and second switches upon rotation of the cam. The first and second casing halves have at least one recess, such as when they are attached to each other, the recesses define an opening, and a part of the cam is received in the opening and it is rotatable therein. One of the first fixed contact is conformed such as when the first and second casing halves are assembled to each other, its part protruding outside the casing, is in contact with the corresponding fixed contact, thus, the use of external bridges is eliminated.