Integrated Proximity Switch Connector for High-Load Tight Spaces
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Solution Overview
Problem
Conventional magnetically-triggered proximity switches are limited in size due to the need for large contacts to accommodate high loads and complex actuation assemblies, which restricts their use in applications with limited space and increases manufacturing time and cost.
Innovation Solution
A quick-disconnect connector assembly with a compact design that integrates a proximity switch within a housing, using magnetic forces to switch positions without an external power source, reducing the number of components and allowing for smaller size and easier installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large contacts are used to accommodate high loads, then the load capacity is improved, but the size of the proximity switch increases
Solution Approach 1:
The patent replaces traditional mechanical contact-based switching mechanisms with a magnetic field-based sensing mechanism. The proximity switch uses a magnetic sensor to detect the position of a magnetically-coupled target, eliminating the need for large physical contacts while maintaining high load capacity through non-contact coupling. This allows the switch body to be significantly reduced in size while still handling high loads.
2Adaptability or versatility
If a complex actuation assembly is used to achieve switching functionality, then the switching capability is improved, but the device complexity and manufacturing time increase
Solution Approach 1:
The patent replaces complex mechanical actuation assemblies with a magnetic field-based sensing system. The proximity switch detects target position through magnetic field changes, eliminating the need for mechanical levers, springs, and contacts. This simplifies the device structure, reduces the number of components, and decreases manufacturing complexity while maintaining full switching capability.
Solution Approach 2:
The patent extracts and eliminates the complex actuation assembly from the traditional proximity switch design. By removing the mechanical actuation components and retaining only the essential magnetic sensing and contactless switching functions, the device complexity is reduced while the core switching capability is preserved.
3Reliability
If a separate housing is used to protect the sensor, then the protection capability is improved, but the overall size of the assembly increases
Solution Approach 1:
The patent merges the sensor housing with the connector housing into a single integrated structure. The connector housing itself serves as the protective enclosure for the proximity switch, eliminating the need for a separate sensor housing. This integration maintains protection capability while significantly reducing the overall size of the assembly, allowing the sensor to be placed in areas with limited free space.
4Adaptability or versatility
If multiple components are used within the switch housing, then the functionality is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent combines multiple components into integrated structures. The connector housing integrates the protective enclosure, mounting features, and electrical connection elements into a single molded piece. The proximity switch is directly mounted within this integrated housing, eliminating the need for separate assembly steps for multiple components. This reduces manufacturing time and complexity while maintaining full functionality.
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
Enables the use of proximity switches in applications with limited space requirements, eliminates the need for a separate housing, and simplifies installation by using magnetic forces to switch positions, reducing manufacturing complexity and costs.
Implementation Method 1
the magnetic flux generated by the target magnet triggers the switching circuit mechanism
Implementation Method 2
using magnetic forces to switch positions
Data Source
Figure 1A~1C
Figure 2
Figure 3A~3C
AI summary
A quick-disconnect connector assembly includes a housing having a bore that extends up to but not through a first end of the housing. The connector assembly also includes a proximity switch disposed within the bore, and the proximity switch includes a switch body, a first contact member, and a second contact member. A portion of each of the first and second contact members extends from the switch body towards a second end of the housing. In a first switch position, a contact of a displaceable switching assembly is in contact with the first contact member, and in a second switch position, the contact is in contact with the second contact member. The connector assembly also includes an external connection assembly including a first pin that is electrically coupled to the first contact member and a second pin that is electrically coupled to the second contact member.