Magnetic Proximity Switch Pivotable Actuator Eliminates Flexible Conductors
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Solution Overview
Problem
Magnetically-triggered proximity switches face limitations due to the need for flexible conductors, such as copper braided pigtails, which can be stiff or have limited current capacity, making them unsuitable for all applications.
Innovation Solution
A magnetically-triggered proximity switch design that eliminates the need for a continuously flexing conductor by using a pivotable actuator assembly with a single moving component, where the common arm acts as a leaf spring to minimize the moment required for switching, allowing for robust and high-current circuit completion without a flexible conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a copper braided pigtail is used to connect moving and stationary components, then flexibility is achieved, but the current capacity is limited and the pigtail may break due to repeated flexing
Solution Approach 1:
The patent removes the flexible conductor (pigtail) from the system entirely. The switching mechanism is redesigned so that the actuator body itself serves as the moving component that directly actuates the switch contacts, eliminating the need for a separate flexible conductor to connect moving and stationary parts.
Solution Approach 2:
The actuator body performs multiple functions: it is both the moving component that responds to magnetic field changes and the structural element that directly actuates the switch mechanism. This multi-functionality eliminates the need for separate flexible conductors while maintaining operational capability.
2Volume of moving object
If the pigtail is made shorter to reduce size, then compactness is improved, but the pigtail becomes too stiff to flex adequately during operation
Solution Approach 1:
By removing the pigtail entirely, the patent eliminates the trade-off between length and flexibility. The actuator body is a rigid component that moves through a defined range of motion, eliminating the need for flexible materials and their associated length constraints.
3Ease of operation
If the pigtail is made longer to improve flexibility, then ease of operation is improved, but the device size increases and the pigtail may break more easily
Solution Approach 1:
The patent eliminates the pigtail and uses a rigid actuator body with defined pivot points and travel limits. This approach provides sufficient flexibility for operation without the size penalties and reliability issues associated with long flexible conductors.
Solution Approach 2:
The actuator assembly is designed with specific pivot points and geometric constraints that define its range of motion. This dynamic design allows the rigid actuator body to achieve the necessary movement for switching operation without requiring flexible materials.
4Ease of manufacture
If a traditional switching mechanism with separate moving and stationary components is used, then the switching function is achieved, but a continuously flexing conductor is required which limits current capacity
Solution Approach 1:
The patent combines the actuator body with the switching mechanism so that the actuator body itself serves as the moving component that directly actuates the contacts. This integration eliminates the need for separate flexible conductors, allowing for higher current capacity while maintaining the switching function.
Solution Approach 2:
The actuator body serves multiple functions: it is the moving component that responds to magnetic fields, the structural element that transmits motion, and the component that directly actuates the switch contacts. This multi-functionality eliminates the need for separate conductors while maintaining switching capability.
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 enhances the reliability and current capacity of the switching mechanism, eliminating the limitations of flexible conductors and enabling effective position sensing without the risks of stiffness or breakage, while maintaining a compact size.
Implementation Method 1
the magnetic flux generated by the target magnet triggers the switching circuit mechanism, thereby displacing the switching circuit mechanism into a second position
Implementation Method 2
the common arm acts as a leaf spring to minimize the moment required for switching
Data Source
AI summary
A magnetically-triggered proximity switch includes an actuator assembly disposed within a switch body, and the actuator assembly includes an actuator body extending along an actuator axis. A primary contact and a secondary contact is each coupled to the actuator body and may be separated from a center contact along the actuator axis. The actuator assembly is pivotable between a first switch position and a second switch position about a pivot axis. In the first switch position, the center contact is in contact with a common contact and the first contact is in contact with a primary contact, thereby completing a circuit between a common arm and a primary arm. In the second switch position, the center contact is in contact with the common contact and the second contact is in contact with a secondary contact, thereby completing a circuit between the common arm and a secondary arm.