Switch Actuator Adapter for Sealed Magnetic Event Detection

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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, lacking mechanical triggering capabilities.

Innovation Solution

A method to convert a non-contact switch assembly into a contact switch assembly by securing an adapter body outside the housing, with an actuation body supporting a target that moves between orientations to activate or deactivate a magnetic assembly within the sealed housing, allowing mechanical contact to trigger the switch without ingress points.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a non-contact switch assembly is used, then the switch assembly maintains a sealed housing without ingress points, 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 single point (non-contact switch sensing area) to a distributed array of sensing points across multiple faces of the housing. This dimensional expansion allows the system to detect targets from multiple directions and locations simultaneously, effectively increasing the detection area while maintaining the sealed housing design.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Area of stationary object

If a contact switch assembly is used, then the detection range is expanded, but mechanical contact causes degradation and failure

Engineering Contradiction:

Improvedetection areaVSAvoidswitch reliability

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The patent replaces the traditional mechanical contact switch mechanism with a non-contact magnetic sensing system. Instead of using physical contacts that wear and degrade, the system uses magnetic assemblies and magnetic targets that detect presence through magnetic field interaction, eliminating mechanical wear while maintaining reliable detection over extended periods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If mechanical contact is implemented, then the switch can be triggered externally, but ingress points are created in the housing

Engineering Contradiction:

Improveexternal triggering capabilityVSAvoidhousing ingress points

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent introduces magnetic fields as an intermediary between the external target and the internal sensing mechanism. The magnetic target on the actuation body interacts with the magnetic assembly through the housing material without requiring physical penetration or ingress points. This allows external triggering capability while maintaining the integrity and seal of the housing structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If the target is positioned outside the housing, then mechanical contact can be avoided, but the actuation body must be movably supported

Engineering Contradiction:

Improvemechanical contact avoidanceVSAvoidactuation body support structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The adapter body serves multiple functions: it provides structural support for the actuation body, enables movable positioning of the magnetic target, and interfaces with the sealed housing. This multi-functional design consolidates what could be separate complex components into a single integrated unit, reducing overall device complexity while achieving the goal of keeping the target outside the housing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 expanded detection range for switch assemblies, combining the benefits of non-contact and contact switches, suitable for hazardous environments and improving switch functionality without mechanical contact degradation.

Implementation Method 1

a magnetic assembly enclosed within the sealed housing... a target configured to magnetically activate the magnetic assembly

Methodology Applied

Scientific EffectMagnetic field detection: Magnetic Field

Data Source

PatentUS20240096576A1Switch Actuator Adapter

Publication Date: 2024.03.21 GENERAL EQUIP & MFG COMPANY INC

AI summary

A method of converting a switch assembly from a non-contact switch assembly to a contact switch assembly to detect an event. The method includes securing an adapter body outside of an enclosed housing of the switch assembly, with an actuation body connected to the adapter body, so that a target connected to the actuation body is supported outside of the enclosed housing by the adapter body and so that the actuation body is disposed to be moved relative to the adapter body from a first orientation to second orientation, upon occurrence of the event, to activate the switch assembly by moving the target between a first location outside of the enclosed housing and a second location outside of the enclosed housing. In one example, the target may be one or more of a magnetic target or a ferrous target.