Designers looking for a robust waterproof limit switch, will almost certainly run across our switches at some point. It’s that “all roads lead to Rome” thing.
Sometimes however, its not just the stainless steel, high electromechanical endurance aspect of our switches that wins the day with engineers and OEM’s. Sometimes, it’s about how easily and flexibly our limit switches can be mounted into an application and how many different types of actuation we support. With over 70 years’ experience designing switches for demanding engine compartment, cab, door, cockpit and valve applications to name just a few, we’ve developed a set of low profile, hardened mounting and actuator combinations that fit into almost any contraption out there. Think “off-the-shelf”. Waterproof Switch Mounting Brackets A picture is worth 1000 words. Check out a few examples of the thousands of mounting configurations we support with off-the-shelf mounting hardware and actuators. Almost any of our sealed pendant switches can be mounted in this hardware, making this one of the most flexible waterproof switch configurations in the world. Surface Bracket With Momentary Switch Pictured here is our E1008 surface bracket used with any of our B series Momentary Waterproof Switches or K Series Waterproof Rocker Switches. This two-piece assembly is made of 304 stainless and welded together for a rock solid, flat surface mounting. A reverse mount option (E1005) isalso available. Right Angle Mount with Simulated Roller In this application our B9112 switch uses a simulated roller actuator to detect mechanical closure for anything from a truck door to a dump body. The mounting bracket is our standard stainless steel right angle mounting bracket. The switch internals are held inside the bracket, sealed in Santoprene including lead connections which can be ordered in any length. The switch itself can be any of our momentary or maintained waterproof pendant switches. Pipe Mount Rocker Switch Our curved metal pipe mount bracket is easily secured to a wide variety of common pipe diameters. Shown here is our K1007 Maintained Contact Rocker Switch. With our standard Neoprene seal, this switch can operate from -60F to 180F without issue and can be specified with current capability up to 15A or endurance to 5 million cycles at lower amp ratings. Angle Mount with double simulated roller Actuator In this configuration, any two of our low profile momentary or maintained pendent switches can be used to create redundant, or complementary sensing of mechanical actuation. All lead connections are sealed within the neoprene coating. Waterproof Roller Limit Switch Roller limit switches of varying angles can be used in many of our bracket configurations including both flush mount and angle mount housings. These switches see diverse usage as safety limit switches for doors, hatches, outriggers, cranes, emergency vehicle systems and much more. Did we Mention Custom? If after all this and more, you still don’t have the bracket or actuator you need, our custom design team is standing by to tweak a high performance switch exactly to your needs. Our switches are all IP68 rated and Military and Space Qualification documentation can be made available for most switches. Give our engineers a call today to discuss your application. Original content posted on https://www.cpi-nj.com/blog/cpi-limit-switches-climbing-that-mounting/ At CPI, we’ve been telling people for years about the robustness and reliability built into every USA designed and manufactured waterproof switch that we make. For applications from recreational vehicles, to advanced military and avionics applications, CPI switch hardware gets chosen because there is just no other solution out there that embodies the “no compromises” philosophy of design and engineering while building such a versatile, durable, and truly waterproof switch. But since we are blue-in-the-face at this point, we’ll just turn it over to one of our recent clients while we catch our breath. Arming Military Aircraft – The GP-19 Gun Pod Designed primarily for helicopters, the GP-19 Gun Pod brings a modular, high reliability solution to the addition of firepower to helicopters and really any other combat ready vehicle. Made by FULCRUM CONCEPTS, of Mattaponi, VA, the GP-19 is packed with features that make it ideal for airborne combat operations The GP-19 gun pod is a modern .50 cal gun made for sustained high rates of fire and designed for maximum reliability. The gun pod contains an integrated ammunition booster motor and a simple ammunition feed system. Because the GP-19 is fully self-contained, it is jettisonable, easily integrated, and aerodynamically optimized. Inherent in the advanced features of the GP-19 is something called the “Last Round Switch” or LRS. This critical system determines when the ammunition magazine is empty (~50 rounds between magazine and gun), so as to facilitate a quick re-load. This means you can quickly reload with a full magazine and not have to load rounds all the way through the system (booster, flex chute, gun feeder etc). The gun also has a LRO (last round override) function which allows for the complete empty of the system if necessary. All of this is critical operation is verified by the position of the last round switch. When choosing what to use for the LRS, the team at Fulcrum Concepts landed on CPI waterproof switches for one primary reason: reliability. The team designed in our r B9111 Waterproof Momentary Switch for use in the system. Key to operation in the anticipated environment are operation over the full Mil-spec temperature range, and an extremely high electromechanical endurance. Our waterproof switch uses a D1040 Plunger Switch mounting for actuation in this application. One of the great flexibilities of the CPI waterproof switch product line is its ability to be mounted in dozens of actuator assemblies, to fit any mechanical constraints in application. Our versatile form factors with their low footprint are unique in the industry. The switch assembly itself is 100% high grade stainless and is truly waterproof, not just water resistant. Our B9111 is a Low Temp version of our Normally open pushbutton pendant switch completely sealed in a santoprene enclosure. Wire lengths are prespecified and shipped sealed in the housing from the factory at whatever length the customer requires. The switch operates reliably down to -40F. The switch can be specified into one of dozens of low profie mounting brackets, or we can custom design one for you. Our basic waterproof switch design has been qualified to over 1 million cycles of electromechanical endurance. High Endurance Switches For Military Applications CPI waterproof switches have found themselves in hundreds of military applications over the years such as:
If you need one of the worlds most reliable waterproof switching solutions for your military grade switching or sensor application, please call us today. https://www.cpi-nj.com Original content posted on https://www.cpi-nj.com/blog/military-grade-waterproof-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/ Hydraulic Multipliers see use in a wide variety of industrial equipment as a cost effective way of driving multiple actuators from a single hydraulic circuit. These systems typically allow the operator to manually activate a conveniently mounted switch which controls a valve diverter. At the right moment, hydraulic pressure is diverted from one circuit to another and back again when done.
Since operators are typically using levers in things like Backhoe’s, Crane’s, Forklift’s, or agricultural sprayers, it is convenient to mount these switches directly on the lever itself where it can be ergonomically reached during operation. These switches are often subject to repeated use and abuse, outdoor environments, and extreme vibration in conditions which pose a safety hazard. The switches need to work, work well, and work for a long time without failure. Typical Hydraulic Multiplier Circuit Using CPI Switches While there are a number of our switches used into this application, your selection will depend on a few key considerations:
Harsh Duty Switches Control Heavy Duty Hydraulics CPI’s line of waterproof switches get used on these kinds of hydraulic multiplier applications because they are just plain hard to kill. In applications like forklifts, telehandlers, backhoe’s, cranes, agricultural machines, or flow control valve hydraulics, there is generally an unfriendly ambient environment that places additional demands on the electromechanical endurance of switches… …CPI switches were designed with that in mind. Call the CPI engineering team today to discuss your switching challenges or visit http://www.cpi-nj.com . Original content posted on https://www.cpi-nj.com/blog/cpi-limit-switches-in-hydraulic-multiplier-applications/ In the world of waterproof switches, designers understand pendant switches to be pushbutton switches that are hand actuated by an actual human. There are typically leads extending from the body of the switch which can allow an ergonomic distance between the operator and the control system. These switches, or sometimes “pendant stations” full of pushbutton switches are designed to control various systems in the factory or on machinery.
This configuration is common, with the button at the end of a cylindrical enclosure, meant to be used for things like nursing call stations, On/Off operator control, or momentary device control where the device is actuated only as long as the operator keeps the pendant depressed. The vast majority of pendant switches you will fine are really of a commercial variety and their target use is for sedate, indoor applications. But for construction vehicles, military equipment, or heavy machinery control, the vast majority of pendant devices you will find lack the robustness and environmental sealing necessary to operate effectively in these deployments. CPI Pendant Switch Solutions Control products makes a complete line of waterproof pendant switches which are specifically designed for the needs of high reliability, high endurance, and complete watertight operation. Couple these with our versatile mounting brackets and what you have is a pendant switch with up to 15A capability that will be ready to work when you need it, no matter what it is exposed to in the interim. K1005 Pendant Switch – This is a maintained contact rocker switch version. This pendant switch has seen many military and non military applications owing to its high tolerance to heat and its extreme electromechanical endurance. Not to mention that it is truly waterproof (ie.. submersible) B7151 Pendant Switch – this is our “high button” momentary closure pendant, also completely sealed in Neoprene and immune to moisture and vibration. Common uses include as a welding torch switch or for motor “jogging” applications. CPI Pendant Switch ApplicationsOur pendants get chosen for any application where there is a potentially wet or outdoor environment and designers don’t want to take chances on the reliability of the switch. Here’s a few examples. THAAD Missle Launch Truck - Build by Oshkosh and Lockeed In this application our K1005-504 is mounted near the wheel well where it can be subject to a fair amount of heat and vibration between uses. Our Neoprene seal extends the temperature range from -65F to 185F and completely seals the switch away from dust, moisture and vibration as well. US Marines Humvee – Built by SAIC. In this application the same K1005-504 is used as a control on the Up-Front-Display Unit inside the vehicle. Industrial Sand Blaster – Clemo Industries In this heavy duty sand blasting machine exposed to extremes of water, dirt, dust and other airborne particulates. A Robustly sealed and washdown proof switch is of extreme importance to these folks. CPI Pendants are Unique Problem Solvers – Call Us Today! When the run-of-the-mill commercial pendant switches just won’t get the job done, our unique capabilities in switch design might be just what you need. We’ve been making high endurance electromechanical switches for the toughest applications on planet earth for over 70 years. Is your application tough enough for our switches? Let’s find out.. This content was originally posted at https://www.cpi-nj.com/blog/sealed-pendant-switches-the-jewels-of-waterproof-switches/ A quick web search for “Waterproof Rocker Switches” yields a universe of rocker switches, made for a universe of applications. Sadly even glorious Google can’t seem to completely sort out the waterproof variety from the more common standard PCB mounted round or rectangular versions and so it is for you the poor system designer to wade through this mess looking for the right rocker switch for your wet and watery application.
Our own rocker switch makes the cut with Google too, with a nice picture on the first page of search results of our K1007 Maintained Rocker. So if you found us and are reading this because of a similar search, then why don’t we just cut to the chase and tell why our truly waterproof pendant style rocker switches may be last waterproof switch you ever need? Rocker Switch Design CPI Rocker switches are part of our family of waterproof switches which we’ve been refining and selling for over 70 years. They are implemented in a style commonly referred to as “pendant switches” owing to their size and form factor. What CPI does is to pair one of our sealed, waterproof pendant switch designs, with an actuator mounting bracket which can allow the switch to be used in an almost infinite number of applications. Some customer even use the switch without any bracket for a manual operator driven application such as a toggle switch on a motorboat winch. A great example of our switch in action is our K1007 SPST Maintained Rocker Switch. With our standard Neoprene seal this switch operates from -60F to 180F without issue and can be specified with current capability up to 15A or electromechanical endurance up to 5 million cycles. And don’t forget that like all our waterproof switches, the K100X series of Waterproof rocker switches is truly waterproof: not splashproof or water resistant. Waterproof Rocker Switch Applications CPI waterproof rockers have been used extensively on military vehicles, in boats, on industrial sand blasters, and in one case as a customization to a Mountain bike used for enduro-racing (See our post on Gravel Grinders). In every case, the common thread for why we are selected has to do with the extremely reliability of the parts, under some of the most challenging environmental conditions and deployments in the world. Call CPI Today to discuss YOUR Waterproof Rocker Switch Application If you’re concerned about part selection for your waterproof rocker switch application, you owe it to yourself to give us a call and discuss it. Our engineers know this stuff cold, we can help. Visit us on the web at https://www.cpi-nj.com. This content was originally posted at https://www.cpi-nj.com/blog/our-waterproof-rocker-switches-rock/ Engineers and system designers looking for reliable switch products often face a quandary. Selection of switches with their inherent mechanical limitations must be pondered carefully or they risk being the proverbial “weakest link” in an otherwise robust control or safety system design.
When switches are directly operated by humans, the equation becomes even more complex. Tactile factors come into play, as well as consideration of the ergonomics of mounting and positioning these switches in vehicles or machinery that may be exposed to severe weather, temperature, vibration or all of the above. Push Button Switch Actuation In addition of offering some of the industry’s most hardened waterproof switch designs, CPI switches come in a number of form factors, suitable for almost any deployment Hand Actuated – CPI Pendant Switches can come in momentary or maintained closure options and are completely submersible. Extended temperature operation is achieved through either Neoprene or Santoprene sealing with leads completely sealed and extending from the switch body in any length required. Both standard and “light touch” actuation versions available. Rolling Ball Switches – Our all stainless steel, rolling ball switch option (J4 series) is ideal for applications requiring a low profile, non-linear activation in a harsh operational environment. The J4 is a patented ball carrier design which prevents contaminates such as mud, dirt, ice, sand, dust, etc. from jamming the ball. Applications include transfer case gear position sensing, neutral safety detection, Hydraulic valve position indication, PTO switching, door switch, backup safety alarm, and interlock switch detection. Plunger Switches – Based on the J4 seal design, our plunger switch allows designers to be sure that waterproof performance can be maintained in extreme environments with electro-mechanical endurance up to 5 million cycles. Plunger size and activation force can be custom specified, and our patented exclusion seal insures the contacts against sand, dust, dirt, mud, rain and pressure washer abuse. Limit Switches – By mounting our pendant switches in a series of enclosures, CPi can offer operational limit switch variations suitable for a wide variety of industrial applications.
For over 60 years CPI has been designing, manufacturing, and qualifying the toughest waterproof switches in the world in thousands of unique applications from fire engines to fishing reels, from steel mills to submarines . When manufacturers want a final solution to their robust switching needs, it usually ends at our doorstep. Please call our team today to discuss your application and vist us at http://www.cpi-nj.com. This content was originally posted at https://www.cpi-nj.com/blog/push-button-switch-types/ Sometimes you need a switch that’s really, truly waterproof. Not just water-resistant or “splash-proof. And if you want one with carefully manufactured durability and extended temperature operation, well you’ve narrowed down the field even further. For tough marine or outdoor applications, CPI’s panel mounted, sealed waterproof switches get the nod after that cheap offshore built switch that seemed so great, starts to fail in the field. Why not start with our switch and save yourself the headache? Basic CPI Pendant Style Waterproof Switch. The internal switching mechanism here is a snap-action copper sine blade spring with a riveted contact. The standard contact material is silver alloy with gold alloy and gold plated silver contacts available upon request. Our switches are even available in low-medium-high configurations so that you can choose the tactile feel you need. There are a few things that make CPI switches the go-to switch when you are done messing around with other implementations.
Our dual panel mount configuration is a good example of a commonly used stock panel mount configuration. In this panel, the twin switches can be wired in series, parallel, or left as individual circuits as shown below. Both vertical and horizontal panels are stock but hey, we can make it look like whatever you need, that’s what we do and we do it right here in lovely East Hanover NJ, not on the other side of the planet. Call CPI for all your Truly Waterproof Switch Panel Needs.If it’s time to think seriously about your toughest marine or outdoor applications, then we really want to talk to you. Call CPI today to ask about all our Waterproof Switches. Ask for Mac. Visit www.cpi-nj.com for more information. This content was originally posted at https://www.cpi-nj.com/blog/cpi-waterproof-switch-panels/ If you’re at all into racing of any kind, chances are you’ve been watching a CPI momentary switch run around the track right in front of your very eyes.
CPI pendant style momentary contact switches are a fairly common fixture on the racing circuit and our newest application includes some racers who are tearing it up on ATV and snowmobile tracks across the country. Nitrous Oxide Racing with ATV’s and Snow Mobiles Nitrous kits are actually a common fixture on many racing circuits. Maybe their most well-known use is on the drag racing circuit, where the power of compressed Nitric Oxide can add some serious horsepower to a drag rig allowing those vehicles to get from 0 to 60 in ridiculous times like 1.6 seconds. In the ATV circuit, a well-placed and carefully utilized nitrous kit is a staple of racing, meant to provide rapid acceleration and deceleration under driver control. For this application the folks at Straightline Performance selected the CPI B7151 Momentary Pendant Switch. A Momentary Switch Designed with Humans in Mind One of the many reasons CPI switches are choosen for demanding performance applications goes beyond just waterproof reliability. The B7151 momentary contact switch is a low force, high activation button variant of our standard switch, allowing operators a definite tactile feel, even when they are wearing gloves! As part of their e-tek nitrous kit, Straightline chose the B7151 for these ergonomic factors as well as its ability to perform as a completely sealed waterproof momentary switch. The B7151 is completely sealed in santoprene and can be ordered with custom lead lengths, and electrical specifications. On the snowmobile racing circuit, the racing is chillier, but the goal is the same. Give your machine that nitrous boost in the wide open straightway. Our momentary switch is typically mounted to the steering wheel and is normally open until depressed, providing added horsepower until released. And it doesn’t matter how wet or cold it gets, our santoprene sealed switch is 100% waterproof and temperature certified down to -20F. CPI Momentary Switches in “Push To Talk” Applications When racing around a track at high rates of speed, talking to your team is critical whether you’re NASCAR, Formula 1, or driving your restored VW in the demolition derby. While racing teams like to keep their choices in technology pretty close to the vest, we can tell you for certain that a few of these folks that you watch on TV are using our B7151 momentary contact switch to keep in touch with the pit crew. Again this switch has been chosen because it provides a large tactile footprint for a gloved hand and extremely reliable operation. It is mounted to the steering wheel where the driver can easily interact with it with their thumb without moving his hands from the wheel. Finding our Momentary Switches. If you believe one of our Momentary Switches might be right for your racing application give us a call. We have many off the shelf variations of this switch to meet most needs. Small quantities of switches are available immediately through distributors like McMaster and Grainger. Typical CPI Momentary Switch variations include:
This content was originally posted at https://www.cpi-nj.com/blog/racing-to-the-finish-with-cpi-momentary-switches/ I know what you’re thinking… What the heck is a Gravel Grinder race? We had to consult the internet too when this application first came to our attention, but it turns out that Gravel Racing is one of the fastest growing bicycle race sports in the country.
Unlike the Tour-de-France, gravel bike racers don’t have a van with a team following them, sponsors, or the lure of big prize money. Terrain can be a combination of asphalt, packed gravel, loose gravel roads, maintenance or B roads, and some single track. The riders are completely self supported and races can run anywhere from 50 to 800 miles. Two of the most popular events are the Dirty Kanza 200 and the Trans Iowa, which are both over 200 miles long and take even the winners, well over 13 hours to finish. If you’re a Gravel Grinder, you’re carrying your world on your bike and your back. Race courses go through parks and mountains, over little rocks, and small Volkswagen sized rocks, where trail signs are few and far between. You are riding in the day, and the night, in the hot sun and the rain and mud. Your pedaling is not only propelling you toward the finish line but like a human hamster on a wheel, it is providing power to a couple critical of critical electrical systems that can make the difference between getting to the finish line, and getting rescued by the park service… That’s where CPI’ waterproof pendant switches come in. Salsa Cycles is a premier maker of Gravel bikes for all levels of off road experiences, including every day folks just looking to perk up their road rides with a little off road fun, as well as serious Gravel Grinder competitors. Our K1005 Waterproof Maintained Contact Pendant switch was recently selected for a modified Vaya touring bike. The switch is designed to control the flow of generator power between the bike’s headlight and the reserve battery. Yes you heard that right, serious Gravel Bikes have a mounted electrical generator that converts the mechanical energy of the biker pedaling, into electrical current. This current can be used to power a headlight or by pressing our K1005 rocker switch, the current can be routed instead to charge an onboard battery. This battery powers the bike's electrical system providing power for driving the Garmin GPS which gives distance, location, and even allows download of the race route. CPI’s K1005 Maintained Contact Rocker Switch was chosen for all the usual reasons: Extreme reliability and completely watertight operation were key as these racers run through pouring rain, mud and humidity, as well as some serious vibration. Another bonus was the light weight and easy mounting of the switch assembly, pictured here mounted on the main crossbar just below the front handlebar assembly. CPI Waterproof Pendant Switches Are Versatile Problem Solvers CPI Waterproof Pendant Switches are designed to meet the challenges of wet, hostile environments and come with a 60 year history of reliable deployment in everything from muddy bicycles, to nuclear submarines. Some of the reasons the switch family has been so successful include:
For those considering new applications for our waterproof switches, we can provide samples to test in your prototypes, and engineers to discuss best practices in how to use them and mount them. Call us today or visit http://www.cpi-nj.com for more information. We love to hear about new applications for our switches. This content was originally posted at https://www.cpi-nj.com/blog/gravel-grinder-bike-racers-reach-out-to-cpi/ |
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