Liftgate manufacturers need to contend with a great many variables as they seek to make their hydraulic lift assemblies operational on the widest possible variety of vehicles. Is it a pickup truck, straight truck, van, or trailer application being used? What are body widths? Will it be a swing up platform or a stowaway gate? What ground clearance and load must it support? Will it cantilever to support uneven ground? The list of considerations goes on well beyond these and fleet managers need to consider all them when designing liftgate solutions for their work trucks. One thing however that seems to be more agreed upon are the requirements of the platform activation switches. These are typically mounted in a fixed position on or near the liftgate. As such they are often exposed to the same conditions as the outside of the vehicle itself, namely rain, mud, dirt, wind, vibration and temperature extremes. Given the propensity for operators to ride up and down on the liftgate, they are often designed to go for the ride too. CPI Switches and Panels for Liftgate Control Because CPI’s switch construction is truly waterproof, not just splash-proof or water resistant, we can create assemblies out of our totally submersible basic switches and stainless steel panels that are perfect for a wet outdoor environment. Our assemblies are used in outdoor applications including lift gate up/down control, construction and mining equipment, as well as engine compartments in transit buses. Most commonly used for liftgate control and positioning is our E1333 seriesdual pushbutton switch panel to raise and lower the lift gates. The E1333 provides a short behind the panel depth requirement making it usable in places where other switches can’t fit. The CPI switch also provides low assembly labor to install with its integral PEM nuts and its packard connector. Lastly as opposed to electronic switches that require power from the circuit to operate the discreet CPI switch is resistant to failures due to poor grounds and its high electromechanical endurance. In fact our “snap action” contact design has been tested to over 500,000 “contactor” electrical cycles. Don’t worry about lead lengths either. Our switches and switch panels can be ordered from the factory at any custom lead length you need. The ability of our switch to withstand abuse at the hands of an operator or mother nature, really sets our products apart for most outdoor applications. And with convenient custom or stock panels, there’s one less piece of engineering you need to do. CPI Custom Waterproof Switch Panels Switch panelscome in a variety of configurations: separate circuits, in-series, and in-series with interlock (to prevent both switches from operating at the same time). We can produce multiple switch panels that also include additional electrical components such as LED indicator lamps per customer specification. CPI Waterproof Switch Panel Features / Options
The Buck Stops with CPI Liftgate Control Solutions Given our durability and worldwide leadership in waterproof switching solutions, it’s likely that our switches will be the last you’ll ever need for your liftgate application. Give us a call today to discuss. Original content posted on https://www.cpi-nj.com/blog/liftgate-engineering-for-work-trucks/ CPI’s X1 thermal switch is being increasingly used by both American and European avionics manufacturers and integrators as their thermal switch of choice for spot detection of overtemperature conditions in systems throughout the aircraft. Recent integrations include FAA approval as a Fenwal replacement on Gulfstream jets, use in the De Havilland “Twin Otter” aircraft, and use by specialty aircraft manufacturer Diamond Aircraft in Europe to name a few of the most recent. But actually, CPI’s thermal switches have been flying around the world in commercial aircraft for decades. The recent uptick in design-ins may have something to do with manufacturers realizing that in addition to superior thermal performance, vibration resistance, and electro-mechanical endurance, our switches are just a whole lot less expensive than Fenwal, and other solutions commonly used. Thermal Switch Uses in Modern Aircraft All modern aircraft employ a number of thermal sensing elements for aircraft systems. So called Spot Fire Detection Systems refer to systems where overheat conditions are monitored at a specific point in a compartment or LRU bay. In order to receive FAA approval, these systems must demonstrate superior detection performance and have the proven ruggedness to survive in the harsh thermal and vibrational environment of modern aircraft. Typical zones on aircraft that employ spot fire detection include:
Several detectors, or sensing devices, are available to solve these detection challenges, encompassing a number of different technologies. Many modern aircraft have some type of thermal switch system or thermocouple system. A thermal switch system has one or more indicator lights or audible alarms that trip when a thermal limit is reached. They are sometimes connected in parallel with each other but in series with the indicator lights. If the temperature rises above a set value in any one section of the circuit, the thermal switch closes, completing the light circuit to indicate a fire or overheat condition. No set number of thermal switches is required; the exact number is usually determined by the aircraft manufacturer. On some installations, all the thermal detectors are connected to one light; on others, there may be one thermal switch for each indicator light. CPI Rod & Tube Series Thermal Switches for Avionics Applications Recently CPI thermal switches like our X1 have seen increasing use as replacements for other thermals owing to their extreme mechanical endurance, setpoint precision, and much lower unit cost making them extremely good choices in spares and retrofit applications. In a recent retrofit application undertaken for a Gulfstream, the CPI X1 thermal switch was qualified to replace the equivalent Fenwal Switch for almost half the cost. The CPI X1 Thermal Switch has 100% equivalent functionality and accuracy with arguably superior electromechanical endurance. CPI’s X1 Series thermal can maintain a setpoint anywhere from 0 to 850F, with a +/- 5F tolerance standard. Tighter tolerances are available. CPI thermal switches are made entirely in the USA at our manufacturing facility in East Hanover New Jersey. For more information, Contact your CPI Solutions team today. Original content posted on https://www.cpi-nj.com/blog/aircraft-fire-detection-spot-fire-detection-systems/ For many applications, standard garden variety ball switches won’t cut it. In fact, even Google is confused about ball switches, conflating them with tilt switches that happen to use a floating ball in their implementation.
But engineers know, that’s not a real ball switch. So for the cognoscenti among us, we understand that a ball switch generally consists of a metal ball in some kind of carrier which when depressed, either opens or closes a circuit. The ball actuator has many uses in applications where mechanical parts pass over the actuation point in an imprecise way. There is no stick or plunger in a ball carrier, and the ball sticks out ever so slightly providing a low profile solution to sensing mechanical position for a wide variety of equipment. For Ball Switches, The Devil Is In The Details So if we are looking at true ball switches, they all have a similar profile. The real difference between ball switches offered on the market and the ball switches CPI makes have to do with four things:
CPI’s J4 Series Ball Switch Design Perhaps the first thing to understand is that unlike virtually every other ball switch in existence, the J4 Series Ball switch is waterproof, period. Not splash-proof or “moisture resistant”. And not just water. The switch rejects oil, gas, dust, sand, mud, ice and all manner of airborne contaminants. Unlike the ball switches of some of our competitors it has no plastic parts. Variations of our switch can operate over a temperature range of -50°F to 185°F without locking up (cold side problem) or failing to make contact. The way CPI has achieved this has everything to do with our patented ball carrier design. As shown below, the J4 ball switch employs a double exclusion seal. This seal coupled with the incredibly tight tolerances achieved in manufacturing, keep contaminants out of the switch housing. An available stainless steel body and internally sealed contacts that can be manufactured in any lead length, complete the picture. Call CPI Today to discuss Your ApplicationIn the world of ball switches, the CPI offering is truly unique. Call our engineering team today to discuss your applications. Original content posted on https://www.cpi-nj.com/blog/j4-ball-switch-for-robust-position-sensing/ The vast majority of thermal switch applications we get have to do with keeping things from getting too hot. Just a few examples of this include:
The list continues but most of these applications are essentially safety systems where our high temperature thermal switch products are uniquely capable and reliable. They detect a high temperature and then close or open to activate a cooling system, an alarm, or a slowdown of the machinery to restore acceptable thermal limits. The Navy’s Phalanx Gun Firing System In an interesting twist on our normal thermal switch applications, one of our SnapStat series, flange mount thermal switches, is being used to heat things up! The Phalanx system is part of a family of military defenses referred to as “Close-in Weapon Systems” (CIWS ) They are designed to engage anti-ship cruise missiles and fixed-wing aircraft at short range. Phalanx is the most heavily deployed CIWS with thousands of these guns mounted on US naval vessels and exported to allies around the world. Like other close-in weapon systems, Phalanx provides ships with a terminal defense against anti-ship missiles that have penetrated other fleet defenses. Phalanx is unique in that it combines search, detection, threat evaluation, acquisition, track, firing, target destruction, kill assessment and cease fire into a single, small deck footprint, mounting. The electronics on Phalanx are complicated and actually work most reliably at a higher operating temperature. In this application our AD006-501 will trigger when ambient temperature in the electronics bay drops below 70F. This activation triggers heaters built into the gun to keep circuit boards in the bay from getting too cold! In this application, our AD006, part of our SnapStat line of thermal switches (0 – 300F) switches almost 10 amps of resistive power. It is set to close-on-fall at 70F but our thermal switches are available in all varients (close on rise, open on fall, etc…) CPI Thermal Switches for Military Applications CPI is certainly a well seasoned supplier of military grade, thermal control components, having produced parts for the US military for over 70 years. We maintain these designs through the years, supporting the military’s upgrade and obsolescence programs, providing drop in replacements when older thermal switches from other manufactures cannot be produced any more. Whether you’re trying to keep it hot or cold in your application. CPI’s thermal switches get the job done. Call our engineering team today! https://www.cpi-nj.com Original content posted on https://www.cpi-nj.com/blog/cpi-thermal-switches-are-heating-up/ When CPI started making thermal switches for the Military in the 40’s, there really wasn’t any other choice. Thermocouple based switches with variable set-points and various temperature ranges of operation were made using the thermocouple materials of the day, mostly copper, aluminum, and chrome. The concept of a thermocouple had been around for over 100 years but CPI switches of that time stood out because they provided reliable operation over an extended temperature range, in an environmentally hardened package suitable for battlefield conditions. Temperature switch technology has evolved over the last 75 years however, and depending on what you’re trying to do, alternate thermal switching technologies abound. For instance, in applications where smaller temperature differences need to be measured with high accuracy (like from 0-100C at 0.01%), technologies like thermistors, temperature sensors tied to external control systems, or simple resistance thermometers may be more suitable and cost effective. Still, traditional thermal switches have evolved too. The variety of types, and use of metal alloy’s has been informed by discovery, experimentation, and improvements in manufacturing processes. Today’s CPI thermal switches come in three basic types, covering a thermal range from 0 to 1750 degrees Celsius. And as always, CPI switches maintain their hardened design making them unique in the world for their electromechanical endurance, and their survivability. Thermal Switch Applications Perhaps one of the best ways to understand the applications that are better suited for thermal switches vs. sensors is to look at common applications for these switches. Galley Temperature Sensors – Prevention of galley fires is critical on both Navy Ships and around any high temperature professional cooking stations. With flash points over 1000 degrees, these systems usually do not have a controller and so local switching to turn of gas supply or raise an alarm is appropriate. Steel Manufacturing – Thermal Switches are used extensively in the steel and iron industries to monitor temperatures and chemistry throughout the steel making process. Disposable, immersible, type S thermocouples are regularly used in the electric arc furnace process to accurately measure the temperature of steel before tapping. The cooling curve of a small steel sample can be analyzed and used to estimate the carbon content of molten steel. Engine Cooling Fan Control – Thermal Switches are commonly used to locally control cooling fans which prevent engine overheat on everything from generators to jet engines. Gas Shut-Off – In systems using pilot lights, a thermal switch will often sense the presence of the pilot and shut off gas flow if the pilot should go out for any reason. Oil Refining – Control of temperature in the oil refinery requires accurate and hardened thermal sensing for many fail-safe systems in the refining process. Avionics Bay Over-Temp – In both commercial and military aircraft, ambient temperature in the avionics bay can reach well over 100 degrees C as components heat up, contributing to early system failure. Thermal switches are used here to economically activate cooling systems. CPI Thermal SwitchesOur three lines of thermal switches include the following.
All switches are characterized by flexible mounting options, highly accurate and programmable set points, and hardened construction for extreme environments. For more information on CPI thermal switches, please contact our engineering team today. Original content posted on https://www.cpi-nj.com/blog/when-to-use-a-real-thermal-switch-not-a-sensor/ Sometimes in engineering design, you just get it right. The right combination of materials, simplicity and elegance. Just the right amount of cleverness. Sometimes it even looks pretty. Sure as time goes on you make tweaks here and there, but if your basic design is sound, reinventing the wheel is seldom necessary.
Such is the case with the CPI J4 Ball Switch, the gift that keeps on giving as it were. Originally designed for military applications on armored vehicles and tanks, this reliable, virtually indestructible waterproof ball switch with our patented seal mechanism keeps getting design win after design win in a variety of control and sensing applications such as:
Most recently the J4 Ball received another design-in at a major manufacturer of armored vehicles. This time it will see use in a transmission sensing application where it provides feedback on gear range inside the transfer case (low, med, high). J4 Ball Switch Operational Niche Our ball switch has a few defining characteristics that make it an excellent choice for certain high endurance applications
CPI Ball and Plunger Switches for Harsh Duty Applications Tough and durable is what we make and who we are. All our products are designed and manufactured in the USA. If you think your application is tough enough for our switches, give us a call today. Original content posted on https://www.cpi-nj.com/blog/j4-ball-switch-a-study-in-hardness-durability/ Almost every large commercial machine with an engine or motor of some sort has a system for monitoring temperature. Critical systems that are thermally controlled can be designed to shut down or throttle operation to prevent system failure or deliver cooling fluids that bring operation back into nominal ranges. In every case these switches must be trusted to prevent compromised safety situations which can cause damage to both man and machines. Depending on the operating temperatures involved, CPI’s Thermal switch products are a go-to solution for hundreds of thermal monitoring applications around the world. Our line has evolved over 50 years to include three distinct thermal switch technologies that can accurately switch at precise setpoints from -20F to 1750F. SnapStat Thermal Switch Applications for Harsh Environments For operating conditions in the 0 to 300o F degree range, CPI has a product line known as “SnapStat” which has been used in hundreds of harsh duty thermal monitoring environments. Just some of these include:
A Versatile, Affordable solution to Over-Temperature Monitoring The SnapStat switch is a close tolerance, bimetal type thermal switch made from all stainless steel and an option for a hermetically sealed design. The nature of the bimetal design makes it extremely resistant to high vibration, extremely accurate and the option for glass sealed, pre-soldered wiring of any length, makes it easy to integrate into your application. Mounting options are equally flexible We can even custom design a custom mounting for your application. For over 50 years CPI has been providing robust thermal switching solutions into robust thermal applications. Give us a call today to discuss your design. Original content posted on https://www.cpi-nj.com/blog/monitoring-equipment-temperature-is-a-snapstat-with-cpi-switches/ The design of the modern work truck is moving forward at an amazing pace. With long haul trucks, the focus has been on collision avoidance systems and advanced controls for fuel economy, but dump truck builders have long had a different focus.
For Dump Trucks, it’s all about safety. Historically, makers of class 8 dump trucks have not exactly been “early adopters” of technology, preferring instead to allow these advances to trickle down after many years of trial by fire on long haul trucks and other vehicles. More recently however, increased safety regulations, modularized construction methods and accelerated adoption rates for technology have conspired to put more and more intelligence in the “Dumb Dump Truck” than ever before. That means an increasingly connected vehicle, with improved fuel economy, and an ever increasing focus on safety systems. Switches Used in Work Trucks Must be Robust It turns out that CPI switches and sensors are critical components of safety systems on dump trucks, work trucks, and many construction vehicles owing mostly to their extremely durable, and watertight operational characteristics. CPI waterproof limit switches have an extremely small pendant switch style form factor and can be mounted in a wide variety of actuation mechanisms, allowing flexible placement in machines and vehicles. They can be sealed in either Neoprene or Santoprene making them fully waterproof and capable of extended temperature operation from -20 to 120 degrees F. And finally, the switches are capable of extremely high electromechanical endurance. CPI has qualified certain switch models to over 5 million cycles of operation. Safety Systems In Dump Trucks and other Work Trucks Here are just a few safety systems that have used CPI limit switches over the years along with the parts commonly used. Dump Body Detection – Our E1092 simulated roller mechanism is mounted easily under the truck bed using one of our waterproof pendant switches like our B9112, NO switch. When the bed is raised, a circuit is completed, raising a visible (and potentially audible) alarm in the cab. This design is used for safety sensing in bucket trucks, loaders, and other vehicles that require mechanical feedback as to boom or bed position. Cab Down Detection – This is a safety interlock switch function, which prevents the system from operating until the hood or cab is closed. While any of our E-series limit switches can be used, CPI actually makes a specific plunger style switch for this application called our J4 Plunger Switch. Originally developed for the military, this switch has an ultra-rugged design featuring a wiper seal and a plunger that can withstand 50 psi to overcome hardened-sand and ice buildup. Neutral Safety – One of the most common safety systems in commercial vehicles is neutral safety detection. In this application, various vehicle operations are prevented until the transmission is confirmed to be in neutral gear. Commonly chosen for this is our J4 ball switch, a hardened, small form factor, stainless steel ball switch designed with our patented seal exclusion system that actually forces contaminants out of the housing every time the ball is actuated. This waterproof switch design is so reliable and robust that it was used to detect the status of torpedo doors on navy submarines. Back Up Alarm – Another common requirement of work trucks is the audible back-up alarm which sounds when the vehicle is moving in reverse. Our E1092 is a great example of a robust limit switch with a simulated lever actuator that is commonly used in this application. Completely made of high grade stainless steel it is truly waterproof, and completely customizable with almost countless mounting and actuator combinations available. This switch can be designed to meet operational standards for military use (B2 series) as well as heavy duty industrial applications (B3 thru B9 series). Parameters such as travel length, current rating, and electromechanical endurance are customizable. CPI has achieved endurance qualifications over 5 million cycles with this basic roller limit switch design. Waterproof Safety Switches for Industrial Use There are hundreds of specialized safety switch applications on dump trucks, work trucks and other industrial vehicles. Those that choose a CPI solution generally do so because they want the most reliable operation in the field that they can possibly have. When the safety of operators is on the line, why would you want anything else? We have a vast amount of off-the-shelf options for our switches. And yet all our switches can be cost effectively customized for custom mounting and electrical parameters. Call us today to discuss your safety switch system requirements with a product specialist. https://www.cpi-nj.com Original content posted on https://www.cpi-nj.com/blog/dump-truck-safety-system-design/ In June of this year, CPI was approached to help sponsor an entry in the 14th International Submarine Race held June 22-26 at the U. S. Naval Surface Warfare Center’s Carderock test tank facility in Bethesda, MD. The contest is an exciting bi-annual event, drawing student engineering teams from around the world who compete to build and race the fastest human powered submarine.
This was the 10th in a series of biennial races sponsored by the ISR every 2 years since 1989, that test the creative skills of young engineering students from colleges, universities and technical and high schools from throughout the world. Teams wear scuba gear to compete in one- and two-person “wet” submarines designed to run along a measured course in Carderock’s 22-foot-deep model basin. U.S. Navy divers provide safety and underwater support. The CPI Submarine – “Watsub” Built by the University of Waterloo, CPI contributed electronic switches from our waterproof switch product line. Since our switches are truly waterproof, not just water resistant or splash proof, they can survive the operational environment of an undersea deployment without compromising their reliability or long life. The Watsub team was particularly interested in our B5114, a normally open pushbutton switch which was set to control critical safety systems in the submarine. Design team member William Klanac was looking for an IP 68 rated switch that would handle a 12V, 0.25A load used in the sub. Ultimately our off the shelf switch with silver alloy contacts was the right choice. “The switch behaved flawlessly in our application, and we were able to pass all wet and dry checks for the competition.” For those with more stringent requirements switches are also available with gold contacts and customizable lead lengths. How did they do? While Watsub successfully passed all operational and safety checks, they were not able to complete the course due to other issues. But this has made the team even more determined. So with effort comes both added experience and added resolve. Watch out ISR, 2019 could be University of Waterloo’s year! CPI Supports the Next Generation of Engineers If you are an educational institution sponsoring engineering programs like the International Submarine Race that have a need for CPI products, contact us today we love to help young engineers get their design on! Original content posted on https://www.cpi-nj.com/blog/cpi-sponsors-international-submarine-races/ The world is full of companies that make a conscious choice to focus on quality and engineering excellence, as opposed to mass producing low cost high quantity commodity goods. Control Products is no exception. CPI decided as a fundamental business philosophy decades ago, that we would operate under a few general principles:
The CPI philosophy has both its challenges and its rewards. For instance unless a client is already familiar with a company’s products, it can sometimes be difficult to sell the quality argument when faced with lower cost competing products whose reps will tell you that they represent “quality” too. In these cases, real quality is not understood until products live in the field for a while and get a good long look at the real world. The Real Cost Of Low Quality I had an Aunt who used to say “…cheap is just another kind of expensive”. Nowhere is this truer than in the area of engineered parts and sub-assemblies for outdoor environments. The problem for equipment manufacturers is that it is simply hard to tell the difference between a switch or sensor that will last and one that won’t. Sometimes it’s just easier to buy the cheapest piece that will do the job and hope for the best. But sometimes, that road leads to expensive in-field failures, often while equipment is still in warranty. The cost and difficulty of replacing these parts instantly becomes a headache manufacturers don’t want. Not to mention the intangible damage to brand perception that comes when large equipment fails due to small compromises in quality. At that point of failure is when many manufacturers turn to CPI for help. After the pain of failure, they’re finally ready to fully receive the quality argument. And if it’s a bit more expensive, so be it because dealing with those field failures really really stinks and no one remembers that you saved a few dollars on the switch while putting the entire machine at risk. The Reliability Road Leads to CPIHere’s a few examples of how this usually goes down:
We have collected hundreds of stories like this over the years, where customers have come to us to meet their quality requirements, after the joy of buying a cheaper part has long receded into memory. The thing is, next time, why not just come to us in the first place? http://www.cpi-nj.com Original content posted on https://www.cpi-nj.com/blog/thoughts-on-quality-when-cheap-is-just-another-kind-of-expensive/ |
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