Compact Safety Switch Assembly With Split PCB and Single Antenna
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Solution Overview
Problem
Existing safety switches for industrial machines and plants are bulky, complicating access control and requiring complex wiring, which hinders miniaturization and increases installation difficulties due to the need for multiple antennas and bulky anchoring spaces.
Innovation Solution
A compact safety switch design where the electronics, including a split Printed Circuit Board (PCB), are integrated within a case and head, allowing simplified connections and reduced component count, with a single antenna aligned centrally for efficient communication, and a locking mechanism that prevents unsafe access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the PCB and electronic components are housed entirely inside the case adjacent to the switch head, then the switching elements and circuits are protected, but the overall longitudinal size of the safety switch becomes at least equal to the sum of the PCB length and head length, making the device bulky
Solution Approach 1:
The PCB is divided into two separate portions: a first portion housed in the case and a second portion housed in the head. This segmentation allows each portion to be optimally positioned in its respective module, reducing the overall longitudinal size while maintaining proper protection and connection of electronic components.
Solution Approach 2:
The PCB portions are connected via a connection element that extends in a direction substantially perpendicular to the longitudinal direction of the switch. This dimensional change allows the PCB to span between case and head without increasing the longitudinal footprint, effectively reducing the overall length.
2Reliability
If multiple antennas are provided to guarantee correct communication regardless of head position, then communication reliability is improved, but the device becomes bulkier and more difficult to install due to the need for larger anchoring spaces
Solution Approach 1:
A single antenna in the head is designed to perform multiple functions: it communicates with the transponder on the actuating device and maintains reliable communication regardless of the head's rotational position. This universal design eliminates the need for multiple antennas while preserving communication reliability.
3Adaptability or versatility
If the head is made orientable with respect to the case by relative rotation, then adaptability to different configurations is improved, but the wiring complexity increases and assembly becomes more difficult
Solution Approach 1:
The connection element connecting the PCB portions is designed to extend in a direction substantially perpendicular to the longitudinal direction of the switch, allowing the head to rotate independently while maintaining electrical connection. This dimensional arrangement decouples the rotational freedom from wiring constraints.
Solution Approach 2:
The PCB is segmented into two portions that can be independently positioned in the case and head respectively, with the connection element providing flexible electrical linkage. This segmentation allows the head to be oriented in different configurations without compromising wiring integrity.
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 results in a more reliable, cost-effective, and compact safety switch with simplified wiring and reduced complexity, enhancing operational safety and ease of installation while maintaining necessary functionality.
Implementation Method 1
a first communication element, usually an antenna, suitable of communicating with a second communication element, such as a transponder, associated with the movable element
Data Source
AI summary
A safety switch for guarding accesses to industrial machines or plants comprises a case which extends along a main dimension defining a longitudinal axis of development, control means housed in the case and suitable for receiving and exchanging signals with the actuating device and/or with the machine or plant and provide with a first PCB, a head connected to the case and adapted to interact with the actuating device upon the opening/closing of the access and wherein the first PCB comprises a first longitudinal portion housed in the case and a second longitudinal portion housed in the head.