Rotary Adjustment for Dual Switch Assembly Calibration
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Solution Overview
Problem
Conventional dual switch sensing/control devices face challenges in cost-effectiveness and efficiency due to manufacturer tolerances, requiring costly and complex parts and time-consuming adjustment methods to ensure simultaneous switch actuation, such as Belleville spring washers or diaphragm systems.
Innovation Solution
The proposed solution involves a sensing device with a rotary adjustment feature, where a circular electrical mounting member on a printed circuit board is rotated within a cylindrical housing to adjust the height of switch actuators relative to an actuatable sensing element, allowing for precise calibration so that both switches change state simultaneously within a tolerance of 0.00005 inches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Belleville spring washers or diaphragm systems are used to synchronize switch actuation, then simultaneous switch operation is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the Belleville spring washers and diaphragm components from the system. Instead of using these mechanical synchronization elements, the invention directly adjusts the electrical mounting member position to achieve simultaneous switch actuation, thereby eliminating unnecessary parts and reducing device complexity while maintaining reliable simultaneous switch operation
Solution Approach 2:
Rather than using complex mechanical elements to force synchronization, the patent inverts the approach by directly adjusting the electrical mounting member position to naturally achieve simultaneous actuation. This reverses the conventional wisdom of adding complexity to achieve synchronization, instead using simplicity to achieve the same result
2Reliability
If Belleville spring washers or diaphragm systems are used to synchronize switch actuation, then simultaneous switch operation is achieved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates expensive Belleville spring washers and diaphragm components from the bill of materials. By removing these costly mechanical synchronization elements and using a simpler electrical mounting member adjustment system, manufacturing cost is reduced while simultaneous switch actuation is maintained through direct position adjustment
Solution Approach 2:
The patent replaces expensive mechanical synchronization components with a simpler, more cost-effective electrical mounting member adjustment system. This substitution uses cheaper components that achieve the same functional result of simultaneous switch actuation without the high manufacturing cost of Belleville springs and diaphragms
3Reliability
If mechanical tongue adjustment methods are used to calibrate switches, then switch synchronization is achieved, but adjustment time increases
Solution Approach 1:
The patent replaces the mechanical tongue adjustment system with an electrical mounting member that can be directly positioned and secured. This substitution eliminates the time-consuming mechanical tongue twisting and positioning process, allowing for faster calibration while achieving the same switch synchronization result through direct electrical component adjustment
Data Source
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AI summary
The present disclosure provides for systems and methods for fabricating sensing and/or control device assemblies, e.g., a dual pressure switch sensing and/or control device, a dual temperature switch sensing and/or control device or the like. More particularly, the present disclosure provides for systems and methods for fabricating sensing and/or control device assemblies (e.g., dual switch sensing and/or control device assemblies) with adjustment features and/or functionalities for switch calibration and/or adjustment, in one embodiment, the present disclosure provides for systems and methods for fabricating sensing and/or control device assemblies (e.g., dual switch sensing and/or control device assemblies) with rotary adjustment features/functionalities wherein the switches of the sensing device may be calibrated or adjusted via the rotary adjustment features/functionalities.