Magnetized Ferromagnetic Contactless Switch for Humid Environments
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Solution Overview
Problem
Conventional mechanically controlled switching devices wear out quickly and are not suitable for humid environments, while contactless solid-state switches using traditional permanent magnets face manufacturing challenges and high costs.
Innovation Solution
A contactless switch with a housing, a magnetic field sensor, and a moveable ferromagnetic element with magnetized legs, where the moveable element is elastically biased and magnetized to detect a magnetic field, allowing for easy assembly and low-cost production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanically controlled contacts are used in switching devices, then the device structure is simple, but the contacts wear out after a given number of operations and the device is not suitable for humid environments
Solution Approach 1:
The patent replaces the mechanical contact system with a contactless solid-state switching system. The moveable ferromagnetic element interacts with a stationary ferromagnetic element through magnetic fields, eliminating direct mechanical contact between switching components. This substitution resolves the wear and humidity issues of mechanical contacts while maintaining a relatively simple device structure through the use of ferromagnetic materials and magnetic field interaction.
2Ease of manufacture
If traditional permanent magnets are used as a source of magnetic field, then contactless switching is achieved, but manufacturing challenges arise and product cost increases
Solution Approach 1:
The patent changes the magnetic field generation approach from using traditional permanent magnets to using ferromagnetic materials that can be magnetized. The moveable ferromagnetic element and stationary ferromagnetic element are designed to create the necessary magnetic fields through their material properties and geometric configuration, rather than relying on permanent magnets. This parameter change simplifies manufacturing and reduces cost while maintaining the contactless switching function.
Solution Approach 2:
The patent uses ferromagnetic materials that can be magnetized to replicate the function of permanent magnets. Instead of using actual permanent magnets, the design employs ferromagnetic elements that generate equivalent magnetic fields when magnetized, providing a cost-effective and manufacturable alternative that maintains the same functional performance.
3Ease of manufacture
If ferromagnetic moveable element with magnetized legs is used, then manufacturing cost is reduced and assembly is simplified, but the device requires magnetic field detection mechanism
Solution Approach 1:
The patent introduces a magnetic field sensor as an intermediary component that detects the magnetic field changes caused by the moveable ferromagnetic element. This sensor acts as a mediator between the ferromagnetic elements and the switching control circuitry, translating magnetic field variations into electrical signals that control the switching operation. This approach allows the use of simple ferromagnetic materials while maintaining reliable contactless switching through magnetic field detection.
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 solution provides a durable, low-cost, and humidity-resistant contactless switching device with improved longevity and manufacturing efficiency by using a ferromagnetic moveable element and a magnetic field sensor for detection, addressing the limitations of traditional switches.
Implementation Method 1
The magnetic field sensor is secured to the housing and positioned to face the plurality of magnetized legs. The magnetic element is configured to detect a magnetic field generated by the magnetized legs as the moveable element is in the engaged position.
Implementation Method 2
The moveable element is made of a ferromagnetic material and comprises a plurality of magnetized legs spaced from each other
Implementation Method 3
The moveable element is elastically biased towards the resting position. the resilient element may be configured to elastically bias the moveable element towards the resting position
Data Source
AI summary
An electrical contactless switch that includes a housing, a moveable element and a magnetic field sensor. The moveable element is made of a ferromagnetic material and is slidably mounted in the housing. The moveable element is adapted to move relative to the housing between a resting position and an engaged position, the moveable element is elastically biased towards the resting position. The moveable element includes a plurality of magnetized legs spaced from each other and at least part of the magnetized legs is slidably guided in the housing. The magnetic field sensor is secured to the housing and positioned to face the plurality of magnetized legs. The magnetic sensor is configured to detect a magnetic field generated by the magnetized legs as the moveable element is in the engaged position. The moveable element is closer to the magnetic field sensor in the engaged position than in the resting position.