Ergonomic Electric Deadman Switch with Modular Cord Assembly
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Solution Overview
Problem
Existing deadman switches, particularly electric ones, are cumbersome to manufacture, assemble, and service, and lack ergonomic features that reduce operator fatigue and strain, which are present in improved pneumatic designs.
Innovation Solution
A modular electric deadman switch with an ergonomic design featuring a body cavity, a removable cover, and an actuator lever hinged at the wrist end to fit natural hand movement, along with a molded cord assembly that reduces twisting and stress on conductor wires, simplifying assembly and enhancing user comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a standard push-button deadman switch is used, then the switch can be manufactured simply, but it causes operator fatigue and is difficult to depress for extended periods
Solution Approach 1:
The patent transitions from a static push-button switch to a dynamic lever-based switch that moves through an arc. The lever is hinged at the wrist end and rotates to follow the natural arc of hand movement, making it easier to operate for extended periods without fatigue while maintaining manufacturing simplicity through the use of a hinge and return spring mechanism
2Ease of operation
If an ergonomic lever design is implemented, then operator comfort and reduced fatigue are achieved, but the switch becomes more complex to manufacture and assemble
Solution Approach 1:
The patent divides the switch into modular segments: the lever assembly (hinge, lever, return spring), the body cavity housing, and the activation switch mechanism. This segmentation allows each component to be manufactured and tested independently, then assembled together, reducing overall assembly complexity while maintaining ergonomic lever design features
3Ease of repair
If a modular design with removable cover is used, then ease of service and manufacturing efficiency are improved, but the device structure becomes more complex
Solution Approach 1:
The patent extracts the cover as a separate removable component from the main body. The cover can be removed to access the activation switch and cord assembly for servicing or replacement, while the main body cavity and lever mechanism remain intact. This extraction approach simplifies service procedures without significantly increasing overall structural complexity
4Reliability
If the cord assembly is rigidly fixed, then electrical connection is reliable, but the cord is prone to twisting and stress on conductor wires
Solution Approach 1:
The patent changes the mounting parameters of the cord assembly by providing a flattened portion on the cord that fits into a corresponding recess in the body cavity. This geometric parameter change allows the cord to be securely positioned without rigid fixation, accommodating natural movement and reducing twisting stresses while maintaining reliable electrical connections through the molded-in conductors
Data Source
AI summary
An electric deadman switch includes a body having a cavity, with an activation switch adapted to be placed in the cavity, and an electrical cord assembly having conductor wires adapted to be connected to the switch, wherein activation of the switch closes an electrical circuit and deactivation of the switch opens the electrical circuit, the electrical cord assembly having an end adapted to be carried in the cavity. A removable body cover is adapted to be placed over the body cavity for securing the electrical cord assembly and the activation switch in the body. The body cavity includes a seat for receiving a mated member and the electrical cord assembly includes the mated member whereby the mated member is seated in the seat when the electrical cord assembly is carried in the cavity to secure the electrical cord assembly in a non-rotating relationship with the body.