Switch Operator Snap-Fit Actuator Shaft Design
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Solution Overview
Problem
Electrical switch assemblies, particularly emergency stops (E-Stops), often require numerous internal parts to provide self-latching and anti-tease features, complicating manufacturing and increasing costs.
Innovation Solution
A novel switch operator design featuring a single piece actuator shaft with a snap-fit cap, a detent assembly biased by springs, and cam surfaces that allow self-latching and anti-tease functionality with reduced parts, enabling the operator to remain in the actuated position until physically released.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous internal parts are used to provide self-latching and anti-tease features, then reliability is improved, but device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent combines multiple functions (self-latching, anti-tease, actuation) into a single integrated switch operator assembly. The actuator shaft integrates the detent mechanism, cam surfaces, and actuation function into one component, eliminating the need for separate internal parts while maintaining all required safety features.
Solution Approach 2:
The actuator shaft serves multiple functions simultaneously: it provides the actuation interface, contains the self-latching detent mechanism, provides anti-tease protection through cam surfaces, and transmits force to the switch mechanism. This multi-functionality reduces part count while maintaining reliability.
2Reliability
If numerous internal parts are used to provide self-latching and anti-tease features, then reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent combines multiple functions (self-latching, anti-tease, actuation) into a single integrated switch operator assembly. The actuator shaft integrates the detent mechanism, cam surfaces, and actuation function into one component, eliminating the need for separate internal parts while maintaining all required safety features.
3Reliability
If numerous internal parts are used to provide self-latching and anti-tease features, then reliability is improved, but material costs increase
Solution Approach 1:
The patent combines multiple functions (self-latching, anti-tease, actuation) into a single integrated switch operator assembly. The actuator shaft integrates the detent mechanism, cam surfaces, and actuation function into one component, eliminating the need for separate internal parts while maintaining all required safety features.
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
Simplifies manufacturing by reducing the number of parts while maintaining self-latching and anti-tease features, ensuring reliable operation and compliance with safety standards.
Implementation Method 1
a pair of detents biased from one another by one or more detent springs that extend through the actuator shaft
Implementation Method 2
A drive spring is disposed in the actuator shaft and extends within the actuator shaft from the cap to a shoulder of the actuator shaft
Data Source
AI summary
A switch operator is provided that includes a single piece actuator shaft coupled to a single piece cap. According to certain embodiments, the actuator shaft may be snap fit to the cap. The cap may include an annular sleeve and an annular skirt that extend orthogonally from the cap. The sleeve includes recesses that receive tabs of the actuator shaft to couple the actuator shaft to the cap. In certain embodiments, the actuator shaft may include slots that allow the actuator shaft to flex upon attachment to from the cap. A bushing encircles the actuator shaft and extends into the cap where the bushing is disposed between the annular sleeve and a skirt. The actuator shaft also includes a pair of diametrically opposed slots that house a detent assembly. The detent assembly may be employed to retain the switch operator in the actuated position and in the unactuated position.