Switch Unit Angular Contact Force Leaf Spring
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Solution Overview
Problem
Existing switch units with proximity sensors face challenges in manufacturing cost efficiency while ensuring reliable electrical contacting and providing precise tactile feedback, as the deformation of elastic elements can alter the actuating force and feedback quality.
Innovation Solution
The contact force from the elastic element is directed at an angle to the actuation direction, with the elastic element and contact element formed in one piece, allowing for reliable contacting and minimal influence on the actuating feedback, using a leaf spring or non-conductive plastic material, and arranged on a stationary carrier or actuating element to reduce component count and enhance assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the elastic element is arranged to contact the contact element in the direction of actuation, then reliable electrical contacting is achieved, but the deformation forces falsify the tactile feedback to the operator
Solution Approach 1:
The contact force direction is changed from parallel to the actuation direction to perpendicular to the actuation direction. This dimensional change in force application allows the elastic element to provide reliable electrical contacting without deforming in the actuation direction, thus preserving the true tactile feedback characteristics for the operator.
2Reliability
If multiple separate components are used for elastic element and contact element, then reliable electrical contacting is achieved, but the component count increases manufacturing complexity
Solution Approach 1:
The elastic element and contact element are merged into a single integrated component. This combining maintains reliable electrical contacting functionality while reducing the total component count, thereby simplifying manufacturing and assembly processes.
3Reliability
If the elastic element deforms in the direction of actuation, then electrical contacting is maintained, but the actuating force required is altered affecting feedback precision
Solution Approach 1:
The contact force is redirected to act perpendicular to the actuation direction rather than parallel to it. This allows the elastic element to maintain electrical contacting through deformation in a different dimension while the actuating force precision remains unaffected, as the elastic deformation no longer occurs in the actuation direction.
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 ensures reliable electrical contacting with minimal impact on tactile feedback, allowing for precise control of the actuating force and reduced component count, enhancing manufacturing efficiency and operator feedback quality.
Implementation Method 1
at least one elastic element (36) which exerts a contact force (48) on at least one assigned contact element (34)
Implementation Method 2
Capacitive proximity sensors can have capacitors whose capacitance changes when the sensor is approached or touched
Implementation Method 3
In the case of inductive proximity sensors, an oscillator generates a high-frequency electromagnetic alternating field
Implementation Method 4
only the frictional force produced as a result of the contact force counteracts the movement of the actuating element
Data Source
Figure 1~2
AI summary
The switch unit (10) has a motion-operating actuator (12) that is in electrical contact with a proximity sensor (20). An elastic component (36) in the form of a leaf spring is joined to apply a contact force on the electric contact portion between the actuator and proximity sensor. The contact force is applied angularly perpendicular to the operation direction (30) of the actuator.