Rotary Switch Catch Mechanism With Integrated Spring Frame
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Solution Overview
Problem
Conventional rotary switches have complex locking mechanisms with multiple parts, leading to high manufacturing and assembly costs, and require greasing, which contaminates the assembly area and increases costs.
Innovation Solution
A locking mechanism using a spring frame with cams engaging a locking wheel, made of plastic, operates in the linear-elastic range, reducing parts and assembly complexity, and eliminates the need for greasing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional locking mechanism with multiple parts (compression spring, ball, sleeve) is used, then the locking function is reliable, but the manufacturing and assembly costs increase and the assembly process becomes complex
Solution Approach 1:
The patent combines the compression spring, ball, and sleeve into a single integrated spring frame component. The spring frame is a closed-loop structure that incorporates the elastic element and the locking ball as integrated features, eliminating the need for separate parts and reducing assembly complexity while maintaining the locking function.
Solution Approach 2:
The spring frame serves multiple functions simultaneously: it provides the elastic force through its material properties, forms the structural framework, incorporates the locking ball, and engages with the locking wheel. This multi-functional design reduces the total number of components needed in the locking mechanism.
2Reliability
If a conventional locking mechanism with multiple parts is used, then the locking function is reliable, but the manufacturing and assembly costs increase
Solution Approach 1:
The patent combines the compression spring, ball, and sleeve into a single integrated spring frame component. The spring frame is a closed-loop structure that incorporates the elastic element and the locking ball as integrated features, eliminating the need for separate parts and reducing assembly complexity while maintaining the locking function.
Solution Approach 2:
The patent changes the material parameter from metal to plastic for the spring frame. This allows the component to be manufactured through injection molding, which is more cost-effective for mass production compared to machining or assembling multiple metal parts. The plastic material maintains the necessary elastic properties for the locking function.
3Ease of operation
If a conventional locking mechanism requiring greasing is used, then the locking function operates smoothly, but the assembly areas become permanently contaminated and additional costs are incurred
Solution Approach 1:
The spring frame's smooth operation is achieved through its own material properties and geometry rather than external lubrication. The plastic material and integrated design allow the locking mechanism to function smoothly without requiring greasing, eliminating contamination and the associated costs and complexity.
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 cost-effective, self-centering mechanism with precise haptic feedback, reducing part count and assembly effort while maintaining service life and eliminating contamination, enabling smaller switching angles.
Implementation Method 1
The locking element consists of a spring frame, with at least one cam engaging the locking wheel being arranged on the spring frame
Data Source
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AI summary
The invention relates to an electrical switch (1), in particular a rotary switch, comprising a rotatable actuation element. A catch mechanism (5) cooperates with the actuation element in such a way that the actuation element can be rotated into catch positions. The catch mechanism (5) consists of an, in particular approximately star-shaped, catch wheel (6) and at least one catch element (7) exerting an elastic force and cooperating with the catch wheel (6). The catch element (7) in turn consists of a spring frame, wherein at least one lobe (8) that engages into the catch wheel (6) is arranged on the spring frame (7).