Rocker Switch Redundant Sensor Segmentation for Magnetic Interference
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Solution Overview
Problem
Existing rocker switch devices for control and operating units in aerial work platforms and construction machines are prone to faults, lack redundancy in switching state detection, and are susceptible to external magnetic interference, posing safety risks in safety-critical applications.
Innovation Solution
A rocker switch device with a detachable actuating element that rotates about an axis, featuring two position elements and two sensor elements arranged to provide independent electrical signal outputs for reliable position detection, and a reset mechanism with a resilient restoring element to ensure consistent neutral positioning, while using magnetic field-generating elements to mitigate external interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sensor element is used to detect switching state, then the device complexity is reduced, but the reliability and redundancy of switching state detection deteriorates
Solution Approach 1:
The switching device is segmented into multiple independent sensing zones with separate sensor elements (first and second sensor elements) positioned at different locations. Each sensor element independently detects magnetic field changes from position elements, providing redundant detection paths that enhance reliability without requiring a completely complex new structure.
Solution Approach 2:
Different regions of the switching device are assigned different functional qualities - the first sensor element monitors one switching state while the second sensor element monitors another switching state. This local differentiation allows each sensor to be optimized for its specific detection task while contributing to overall system reliability.
2Ease of manufacture
If traditional rocker switch structure is used, then the ease of manufacture is improved, but the susceptibility to external magnetic interference deteriorates
Solution Approach 1:
Magnetic field-generating elements (permanent magnets or electromagnets) are introduced as intermediary components between the mechanical switching action and the sensor detection. These intermediaries convert mechanical position changes into magnetic field changes, which are then detected by the sensor elements, providing isolation from external magnetic interference while maintaining manufacturability.
3Device complexity
If mechanical microswitches are used, then the device complexity is reduced, but the life expectancy and durability deteriorate due to high wear and tear
Solution Approach 1:
The traditional mechanical contact-based microswitch mechanism is replaced with a magnetic field-based detection system. Position elements with magnetic field-generating elements interact with sensor elements through magnetic fields rather than direct mechanical contact, eliminating wear and tear on switching components while maintaining relatively simple device architecture.
4Device complexity
If the entire switch module must be removed for repairs, then the device complexity is reduced, but the ease of repair deteriorates
Solution Approach 1:
The switching device is segmented into separable components - the actuating element can be detached from the housing, and sensor elements are positioned to allow individual access. This segmentation enables repair personnel to service or replace specific components without removing the entire switch module, improving ease of repair while maintaining structural simplicity.
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 reliable and redundant evaluation of switching processes, reduces susceptibility to temperature changes and external magnetic fields, ensuring safe and reliable operation in safety-critical applications by ensuring consistent neutral positioning and independent signal detection.
Implementation Method 1
at least two sensor elements are arranged opposite the position elements on or in the housing in order to detect a position and/or a movement of the actuating element
Implementation Method 2
A magnetoresistive element for detecting a switching operation is also arranged below the plate
Implementation Method 3
WO 2002/13387 A1 describes a rocker switch device glued to a plate with a permanent magnet integrated in the rocker switch, which is also moved when the rocker switch is moved. Another magnet is arranged in the housing of the rocker switch, which holds the rocker switch in a defined position when it is not actuated. A magnetoresistive element for detecting a switching operation is also arranged below the plate
Data Source
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AI summary
A control and operating unit for a mobile elevating work platform, a mobile work machine, or a construction machine comprises at least one rocker switch device (116) which includes a housing (128a, 128c) and an actuating element (126) detachably attached to the housing (128a, 128c). The actuating element (126) is movable about at least one axis of rotation relative to the housing (128a, 128c) and comprises at least two position elements (142a, 142b). At least two sensor elements (156a, 156b) opposite the position elements (142a, 142b) are arranged on or in the housing (128a, 128c) to detect a position and/or a movement of the actuating element (126).