Electric Switch Actuator Lever Design for Extended Travel
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Solution Overview
Problem
Existing electric switches with additional actuators face limitations in extending actuating travel without increasing the stress on the switching element, and are prone to damage from improper use forces.
Innovation Solution
The actuating lever is mounted to a side surface and extends over the upper surface of the housing, allowing for additional over-travel without damaging the switching element, with a stop preventing further movement of the actuating plunger and the lever making contact with the housing edge to resist excessive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the actuating lever is mounted on the side surface and extends over the upper surface of the housing, then the actuating travel is extended with a long over-travel after switching, but the switching element may be damaged by forces from improper use
Solution Approach 1:
The actuating plunger serves as an intermediary element between the actuating lever and the switching element. It absorbs and transmits the actuating forces while protecting the switching element from direct exposure to improper use forces. The plunger's linear movement path and connection to the lever create a mechanical buffer that maintains reliability while enabling extended travel.
Solution Approach 2:
The stop arranged in the switch housing provides beforehand cushioning by limiting the movement of the actuating plunger. This stop prevents the plunger from moving beyond a certain point, thereby protecting the switching element from damaging forces that could result from excessive actuating travel or improper use, while still allowing for extended operational over-travel.
2Length of moving object
If a force is applied to the end of the additional actuator, then the switching travel is increased by a linear factor, but the actuating force required becomes correspondingly lower
Solution Approach 1:
The actuating lever is mounted on the side surface of the housing rather than directly on the actuating plunger's axis. This dimensional change in mounting location creates a lever arm that provides mechanical advantage, allowing forces applied at the extended end of the lever to be transformed into effective actuating force on the plunger, thereby increasing switching travel while reducing required actuating force.
Solution Approach 2:
The actuating lever is designed to be movable and pivotable with respect to the housing, allowing it to dynamically adjust its position during actuation. This dynamic configuration enables the lever to optimize its mechanical advantage throughout the range of motion, facilitating increased switching travel with reduced actuating force requirements.
3Ease of operation
If the actuating lever is allowed to move further after switching, then an additional over-travel is permitted, but the switching state changes unintentionally
Solution Approach 1:
The actuating plunger acts as an intermediary that decouples the actuating lever's movement from the switching element. The lever can move freely through its full range including over-travel, while the plunger only transmits force to the switching element within the precise range needed for reliable switching, thereby maintaining switching state stability despite extended lever movement.
Solution Approach 2:
The stop in the housing provides beforehand cushioning by defining the precise limit at which the actuating plunger can move. This stop ensures that the switching element is actuated only within the correct range, preventing unintentional switching state changes even when the actuating lever is moved further for ease of operation or to provide tactile feedback.
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
This configuration reduces the load on the actuating plunger and lever, enabling extended actuating travel without changing the switching state and preventing damage from improper use forces, while allowing the actuating lever to resist forces through a counterforce.
Implementation Method 1
an actuating lever (4) mounted on and pivotable or otherwise movable with respect to the housing
Implementation Method 2
For a force acting upon the end of the additional actuator switching travel is increased by an approximately linear factor in relation to the switch without an additional actuator and the actuating force is correspondingly lower
Implementation Method 3
The resilient actuating lever according to the invention... If yet more force is applied to the actuating lever, the free end of the actuating lever can be bent over the edge, and in doing so the lever of the actuating lever is shortened due to the new contact point at the edge of the housing. The actuating lever is now able to resist the contacting forces through the application of a higher counterforce.
Data Source
Figure 1~3
Figure 4~6
AI summary
An electric switch has a housing with an upper surface (2) through which a actuating plunger (3) extends at a position close to a side surface. The actuating plunger is arranged to operate a switching element disposed inside the housing. An actuating lever is fixed to the side surface adjacent the plunger such that the actuating lever (4) extends over and beyond the upper surface (2) of the housing (1). A stop for the actuating plunger (1) is arranged inside the housing (1). With this switch the actuating travel is extended solely in relation to the switch. Furthermore a long over-travel exists following switching, wherein any forces which might occur through improper use in relation to the switch do not cause any damaging effects to the switching element.