Quiet Electromechanical Switch with Cam Actuation
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Solution Overview
Problem
Conventional electromechanical switches are noisy and require large rotational angles for actuation, and their installation methods are inefficient, leading to alignment issues and safety hazards during retrofitting.
Innovation Solution
A modular electromechanical switch mechanism with a small angle of rotation and a modular framing system that allows for secure installation without fasteners, featuring a housing with pivot arms and a camming element to separate switch contacts quietly, and a frame member that completes the electrical enclosure to prevent exposure to live wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a pendulum-type toggle switch with paddle actuator is used, then the switch is easy to operate with small rotation angle, but it produces loud noise when contacts close
Solution Approach 1:
A cam element is introduced as an intermediary between the actuator mechanism and the switch contacts. The cam element converts the rotational motion of the actuator into controlled linear motion that gradually closes the contacts, mediating the interaction to eliminate impact and noise while preserving ease of operation.
Solution Approach 2:
The switch mechanism transitions from a static rigid connection to a dynamic cam-based system. The cam profile is designed to provide controlled motion characteristics during actuation, allowing the contacts to close smoothly rather than through sudden impact, thereby reducing noise while maintaining operational ease.
2Object-generated harmful factors
If a toggle switch with large rotation angle (40-60°) is used, then the switch contacts are quiet, but the actuator must rotate a large distance requiring deliberate user action
Solution Approach 1:
The cam element introduces dynamic motion control, allowing the actuator to rotate through a small angle while the cam mechanism translates this into the necessary contact separation distance. This dynamic transformation enables quiet contact operation without requiring large actuator rotation angles.
Solution Approach 2:
The mechanism transforms the motion from a single rotational dimension to a combined rotational and linear dimensional movement through the cam profile. The actuator rotates slightly while the cam converts this to linear contact separation, achieving quiet operation with minimal actuator rotation.
3Ease of manufacture
If conventional switch installation methods are used, then the switch can be installed, but alignment issues occur and fasteners may expose live wiring creating safety hazards
Solution Approach 1:
The switch device includes an integrated frame member with built-in alignment features and enclosure structures that self-align during installation. The design provides inherent guidance and positioning mechanisms that eliminate the need for separate alignment operations and fasteners, allowing the switch to self-install safely without exposing live wiring.
Solution Approach 2:
The frame member merges multiple functions into a single integrated component: structural support, alignment guidance, electrical enclosure, and mounting attachment. This consolidation eliminates separate alignment steps and fasteners that could expose live wiring, providing both ease of installation and safety in one unified structure.
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 quiet and easy-to-operate switch with reduced noise during actuation and eliminates the need for fasteners, ensuring safe and efficient installation, aligning with various form factors and décor changes, while maintaining electrical safety.
Implementation Method 1
A camming element disposed on the second switch portion is configured to rotate a second angular amount in the second direction. The predetermined minimum distance is a function of the first pivot arm length and the second pivot arm length.
Data Source
AI summary
The present invention is directed to a switch device that includes a first switch portion that is configured to rotate a first angular amount in a first direction about a first fixed axis of rotation and has a first pivot arm length. The first and second switch are coupled to the interface portion. The second switch portion rotates a second angular amount in a second direction and has a second pivot arm length. The second angular amount is greater than the first angular amount and a function of the first pivot arm length and the second pivot arm length. A set of switch contacts includes at least one fixed contact and a movable contact separated by a predetermined minimum distance that is a function of the first pivot arm length and the second pivot arm length.