Electromagnetic Safety Switch Lock with Integrated Mounting
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Solution Overview
Problem
Conventional safety switches with a lock function using an electromagnet and a magnetizable member are larger in size, and there is a need for a more optimized shape of the electromagnet to address this issue.
Innovation Solution
A safety switch design that includes a detection unit, a safety signal output unit, a lock input unit, and a drive control unit, utilizing an electromagnet with a specific shape and attachment portions to minimize size while maintaining functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lock function is added to the safety switch using an electromagnet and magnetizable member, then the safety and prevention of accidental door openings are improved, but the device size increases
Solution Approach 1:
The electromagnet serves dual functions: it acts as both the locking mechanism component and the attachment portion for fixing the switch body to the installation location. This integration eliminates the need for separate attachment components, thereby reducing overall device size while maintaining the lock function.
Solution Approach 2:
The electromagnet is designed to perform multiple roles: generating magnetic force for locking, providing mechanical attachment through its housing, and serving as the mounting interface for fixing the switch body. This multi-functionality reduces the number of separate components needed, addressing the size increase problem.
2Volume of stationary object
If the electromagnet shape is optimized for compactness, then the device size is reduced, but the magnetic attraction force may be compromised
Solution Approach 1:
The electromagnet housing is designed with locally optimized features: the first housing portion provides magnetic pole surfaces for attraction, while the second housing portion provides attachment surfaces. This local differentiation allows compact overall dimensions while maintaining sufficient magnetic force at the attraction surfaces and mechanical strength at the attachment surfaces.
Solution Approach 2:
The electromagnet design optimizes parameters such as the thickness of the housing portions, the area of magnetic poles, and the positioning of attachment surfaces to achieve the right balance between compact size and adequate magnetic attraction force for the intended application.
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
The design allows for a downsized safety switch with improved detection accuracy and sensitivity, preventing unauthorized opening of safety gates and enhancing production efficiency by reducing unnecessary shutdowns.
Implementation Method 1
an electromagnet on which an attraction surface corresponding to the surface to be attracted is formed
Implementation Method 2
a lock function using an electromagnet and a member to be magnetized
Data Source
AI summary
A safety switch that has a lock function using an electromagnet and a member to be magnetized is downsized. The safety switch includes: a detection unit that detects that a movable actuator is within a predetermined range; a safety signal output unit that outputs a safety signal based on a detection result obtained by the detection unit; an electromagnet; a lock input unit that receives a lock instruction for locking movement of the actuator; a drive control unit that drives the electromagnet based on the lock instruction received via the lock input unit; and an attachment portion which is formed on the electromagnet and fixes a switch body to an installation place of the switch body.