Switch Actuator Adapter for Sealed Contact Triggering

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Solution Overview

Problem

Conventional contact switches require mechanical contact and ingress points, which can lead to degradation and failure, while non-contact switches have limited detection range and area, making them less effective in certain environments.

Innovation Solution

A switch assembly that converts a non-contact switch to a contact switch by using an adapter body and actuation body to move a target between activation and non-activation positions, allowing mechanical contact to trigger the switch without entering the housing, thus combining the benefits of both types.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a non-contact switch is used, then the switch has no ingress points and is sealed, but the detection range and area are limited

Engineering Contradiction:

Improvesealed housing reliabilityVSAvoiddetection area

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent extends the detection capability from a fixed point (non-contact switch sensing area) to a movable line or area by attaching the non-contact switch to a movable arm. This dimensional change allows the detection zone to sweep through space, dramatically increasing the effective detection area while maintaining the sealed housing benefit.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent introduces a movable arm or linkage as an intermediary between the sealed non-contact switch and the target object. This mediator transmits mechanical motion to reposition the switch, enabling extended detection coverage without compromising the sealed housing design.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If a contact switch is used, then the detection range and area are enhanced, but mechanical contact and ingress points cause degradation and failure

Engineering Contradiction:

Improvedetection areaVSAvoidswitch reliability

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The movable arm acts as an intermediary that allows mechanical motion and extended detection range while preventing direct contact between external objects and the switch housing. This eliminates ingress points and maintains reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the traditional mechanical contact switch with a non-contact switch that uses magnetic or capacitive sensing. This substitution eliminates wear and degradation associated with mechanical contacts while maintaining the ability to detect objects at extended ranges through mechanical positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If a non-contact switch is converted to a contact switch configuration, then mechanical contact detection is enabled, but the switch housing must have ingress points

Engineering Contradiction:

Improvemechanical contact detectionVSAvoidhousing seal integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent uses a non-contact switch (magnetic or capacitive sensor) instead of a traditional mechanical contact switch. This allows mechanical contact detection capability through magnetic targets or ferrous material detection without requiring physical ingress points in the housing, maintaining seal integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The movable arm serves as an intermediary that enables mechanical contact detection by positioning the sealed non-contact switch near targets without requiring the switch housing itself to have ingress points. The external movable structure provides the contact interface while the internal switch remains sealed.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables a sealed, reliable, and adaptable switch solution that can detect mechanical contact without ingress points, enhancing detection range and area, suitable for hazardous environments and existing installations.

Implementation Method 1

The magnetic assembly is configured to be selectively activated to move the switch assembly between a first state and a second state

Methodology Applied

Scientific EffectMagnetic activation: Magnetism

Implementation Method 2

The target is at least one of a magnetic target or a ferrous target

Methodology Applied

Scientific EffectMagnetic target interaction: Magnetic Field

Data Source

PatentUS11837421B2Switch actuator adapter

Publication Date: 2023.12.05 GENERAL EQUIP & MFG COMPANY INC

AI summary

A switch assembly for adapting a non-contact switch into a contact triggered switch, such that the internal electrical state of the non-contact switch can be triggered by mechanical contact with an object or surface. The switch assembly can include an adapter body coupled to the non-contact switch and an actuation body coupled to the adapter body. The actuation body can be movable relative to the adapter body to selectively position a target supported by the actuation body within a sensing region of the non-contact switch. The actuation body can be moved by an external object making contact with a portion of the actuation body.