A common reliability acronym that applies to all types of components and subassemblies is MTBF, Mean Time Between Failure. If you’re an engineer concerned about the reliability of your switch in a hostile, demanding operational environment, then you’re worried about a type of rating called electromechanical endurance (EE).
Electromechanical endurance is usually defined in terms of how many switching operations can be performed under certain conditions before failure. These numbers are affected by a number of parameters including:
So what constitutes excellent reliability for a waterproof switch, and how does a manufacturer go about achieving it? How Does CPI Make Reliable Electromechanical Switches? Typical endurance specifications for electromechanical switches in military and industrial applications can run anywhere from to 1 to 5 million cycles depending on the aforementioned factors. Achieving this requires tight specifications related to travel parameters and electrical requirements, carefully controlled through the manufacturing process. Key to being able to build a switch with electromechanical endurance of over 5,000,000 cycles is an extensive knowledge of how every switch design parameter affects operational reliability at the limits. We’ve learned the hard way how electrical configuration can prevent contact freezing at low temperature; how to prevent contact chatter in vibrational environments: or how to handle startup electrical loads that contribute to early switch failure. Key to solving these problems is the broad array of actuator, travel, and mounting configurations we have deployed into a diverse array of field applications over the years. Once our engineers have selected and designed the combination of elements that best meet the application need, then it is time to field test. Time and time again we have seen that no amount of bench testing can duplicate field trials where unforseen (and often unspecified) requirements are imposed on the design. Solving these problems finally leads to better more reliable switch operation and informs our production testing leading to more reliable parts all around. Another key to delivering robust electromechanical switches is the reliable manufacturing and testing of custom parts in production quantities. While CPI manufactures and produces many standard parts, it is in custom manufacturing that we really excel. All our design and manufacturing is done in the USA, we do not outsource design or primary manufacturing. Not only does this insure higher quality and consistency, but we are cost competitive with switches built overseas that are bulkier, and far less robust. They are “splashproof”, and “Water-resistant”, but our sealed switches are truly waterproof. At CPI we long ago committed to remaining a “Made in the USA” company. We think it shows. Please contact us to discuss your application for one of our high electromechanical endurance switches. Original content posted on https://www.cpi-nj.com/blog/looking-at-electromechanical-endurance/ While many of the most demanding applications for our waterproof switches exist in military vehicles, planes, offshore drilling equipment, naval vessels, and mining and drilling equipment, it turns out that our switches have found a home in wide range of specialty vehicles, recreational vehicles, and farm vehicles too. Switch uses in these vehicles vary, but the common thread is the requirement for reliable operation and longevity under potentially abusive environmental conditions.
Back Up Alarm Switch – Anyone who’s worked in construction or walked through a Home Depot has heard that high loud beeping sound as a dump truck or Forklift operates nearby. Construction Vehicles, Forklifts, delivery trucks, dump trucks and farm combines are just a few of the places you will find our E1 series limit switches activating a variety of audible alarms. Since this equipment usually needs to operate outdoors it is important for this application to have a truly waterproof switch capable of driving a variety of current loads. Cab Closed Interlock Switch – Originally designed for the Military, our J4 plunger switch has seen operation in a variety of Safety Interlock applications on a wide variety of vehicles. Our rugged design comes with a wiper seal and a plunger that can withstand 50 psi to overcome hardened-sand, complete operation underwater, or ice buildup. Start Switch – Whether its your Jet Ski, Snowmobile, or your Quad, you need a start switch which won’t fail in a saltwater, or outdoor environment. These are vehicles that are designed to be abused, and the switches in them better be designed that way too. Our D1040D is a panel mount version of our waterproof plunger switch which is pretty much ideal for this purpose. Kick Stand Down Detection – Communication systems used on police motorcycles rely on our E1092 series switches to provide seamless flow of communications to police dismounting their vehicles. Our switch is mounted to the kickstand using a custom bracket and reliably detects tell them when the kickstand is down so that helmet audio sources can be rerouted instantly. Our switch replaced a competitors limit switch that failed constantly due to the high vibration environment, and its inability to handle the actuator overtravel common to real world use. Contact CPI Today There are dozens of other non-automotive vehicular applications for our waterproof switches. To find out more information visit www.cpi-nj.com. This content was originally published at https://www.cpi-nj.com/blog/waterproof-switches-for-specialty-vehicles/. |
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