Limit Switch Diode Integration for Automatic Assembly
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Solution Overview
Problem
The conventional assembly of limit switches in linear actuators is time-consuming and labor-intensive due to the manual welding process required for connecting the limit switch and diode, making it difficult for automatic production.
Innovation Solution
A limit switch design that eliminates the need for diode welding by integrating a diode within the insulation housing, using a press block, connection pins, and an elastic connection guiding set to establish electrical connections, facilitating automatic production and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual welding is used to connect the limit switch and diode, then reliable electrical connection is achieved, but assembly time increases and labor consumption increases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical insertion system. The diode is inserted into the insulation housing and electrically connected to the limit switch through conductive components without any welding operation, thus eliminating the time-consuming welding step while maintaining electrical connection reliability through the mechanical fit and conductive path design.
Solution Approach 2:
The patent merges the diode and limit switch assembly into a single integrated unit housed within the insulation housing. By combining these components into one assembly that can be installed as a single unit, the patent eliminates the separate welding operation and reduces assembly steps, thereby improving productivity while maintaining reliable electrical connections through the integrated design.
2Reliability
If manual welding is used to connect the limit switch and diode, then reliable electrical connection is achieved, but assembly complexity increases
Solution Approach 1:
The patent segments the electrical connection system into distinct functional components: the insulation housing, the diode, the limit switch, and conductive connection elements. Each component has a specific function and can be independently manufactured and inspected, reducing assembly complexity while ensuring reliable electrical connections through the defined interfaces between segments.
Solution Approach 2:
The patent replaces the complex welding process with a simple mechanical insertion and contact system. The diode inserts into the housing and makes electrical contact through conductive elements without requiring welding equipment, skill, or post-welding inspection, thereby reducing assembly complexity while maintaining connection reliability through precise mechanical fit and conductive path design.
3Ease of manufacture
If diode is connected externally to the limit switch, then electrical connection is established, but assembly time increases
Solution Approach 1:
The patent merges the diode connection into the limit switch housing structure, creating an integrated assembly. The diode is positioned within the insulation housing and electrically connected through built-in conductive elements, eliminating the need for separate external connection steps and reducing assembly time while simplifying the manufacturing process through integration.
Solution Approach 2:
The patent performs preliminary assembly of the diode within the insulation housing before final installation. The diode is pre-positioned and electrically connected to the limit switch components within the housing, so that when the entire assembly is installed, the electrical connection is already established, eliminating time-consuming on-site wiring or welding operations.
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 simplifies the assembly process, reduces labor, and enables automatic production by eliminating the need for manual welding, while maintaining effective power supply control through the diode and limit switch.
Implementation Method 1
The elastic connection guiding set includes an elastic unit pressed by the press block and a connection guiding sheet connected to the elastic unit
Implementation Method 2
The limit switch takes advantage of the rectifying function provided by the diode (3a) to allow the current to only flow in one direction and to block the current flowing in the reverse direction
Data Source
AI summary
In a linear actuator, a limit switch includes an insulation housing formed with an opening and plural slots; a press block disposed on the insulation housing and exposed outside the opening; a pair of connection pins disposed in the insulation housing and spaced with an interval, and respectively protruded from the slots; an elastic connection guiding set including an elastic unit pressed by the press block and a connection guiding sheet connected to the elastic unit, wherein the connection guiding sheet are connected to the pair of connection pins; and a diode disposed in the insulation housing and including two guide pins, wherein the two guide pins are respectively and correspondingly connected to the pair of connection pins in the insulation housing. Accordingly, the electrical connection for the limit switch is simplified thereby facilitating automatic production.