CPI switches continue to see broad acceptance across the work truck industry, for applications where manufacturers are just tired of dealing with switch failures or unreliability in the field. Work trucks have a few operational characteristics that makes switch toughness and reliability a key consideration.
In short, this class of vehicles was born to use CPI’s hardened waterproof switches for many of their primary operator control switches, or safety limit switch applications. In 2018, here are just some of the work truck applications our switches have been designed into. Work Truck Application for CPI Waterproof Limit Switches Outrigger Locking Detection– On bucket trucks, fire engines, cranes, and other vehicles that use outriggers for stability, CPI Waterproof Limit switches detect when the outrigger is full extended and locked into position. PON/POFFApplications – On many types of work trucks, supplementary hydraulic controls require operator manipulation to turn on and off. CPI Pendant style switches are completely sealed and provide the electromechanical endurance operators need to turn on or manually control critical equipment. Liftgate Control– A common application for our switches is to control the up and down motion of a liftgate, especially since these systems are often mounted outside, on the liftgate itself. Dump Body Detect– Stories of dump trucks flying down the highway with the dump body up are sadly, all too real. Dump truck manufacturers need a reliable safety limit switch like our B9112 to raise alarms in the cab when the dump body is extended. Cranes– Whether they be truck mounted cranes or full construction cranes, cranes of all types and sizes have made use of our E1 waterproof limit switches in anti-two-block safety systems owing to their robustness and small form factor. They also use our J4 ball switch in hydraulic valve position detection applications using our specialized valve mounting brackets. Sanitation Trucks – Use our waterproof limit switches pre-mounted into a stainless steel control panel to control compressor and lift gate operations on the vehicle. Weatherproof Switch Panels– CPI has custom made switch panels and wiring for all kinds of vehicles who want a weatherproof, prewired option. Luckily all our waterproof switch come with panel mounting capability for use in any application. CPI Safety Limit Switches were Made for Work Trucks…On Work Trucks costing upwards of $100,000, its seems silly to take a chance on safety system sensors, with cheap, offshore produced switches. All CPI switches are designed and made in the USA right here in our East Hanover NJ Factory. Despite this, our switches often cost less in quantity than comparable switches by Honeywell, Eaton, and Otto. We love solving problems of safety and sensing with our switches. Please give us a call today.https://www.cpi-nj.com Original content posted on https://www.cpi-nj.com/blog/cpi-switches-solve-problems-for-work-trucks/ 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/ For many applications requiring robust toggle switch functionality CPI sealed, waterproof toggle switches can be a good solution. Whether your application ishand actuated or needs be actuated mechanically, we have a complete off the shelf part configuration that incorporates all the necessary switch electrical parameters as well as an appropriate mounting bracket for your application. The niche for our switches is really for applications that are in wet, or outdoor environments, or environments that get a lot of heat and vibration. That’s because we manufacture our base pendant style switches with either a Santoprene or Neoprene coating. Not only does that make them completely waterproof (not water resistant or “splash proof”) but it makes them operational in extremes of temperature or toxic environments. CPI Switches in Action – Marine Toggle SwitchesCPI switches have seen hundreds of uses as boat toggle switches and marine rocker switches over the years. Here are some examples of specific CPI toggle switches in real-world marine applications. Engine Start/Kill – Mounted in one of our custom waterproof switch panels, Or K1 series toggle switches have been used as start/stop switches on work-boats and other commercial fishing boats owing to their extremely high durability and of course, completely waterproof operation. Horn and Signal Operation – In the same panel our switches which are rated to 28VDC and 5A can be used to control manually activated onboard horns or alarms. Bulkhead Lighting Controls – CPI switches can be used to control bulkhead lighting either manually or automatically when used in a door open/closed configuration. Bilge Pump Control – Our K1007 SPST Maintained Rocker Switch. sees use as a toggle switch for bilge pumps in everything from jet skis to commercial fishing boats. For expert help with your waterproof toggle switch application, call the team at CPI today. Original content posted on https://www.cpi-nj.com/blog/waterproof-toggle-switches-for-marine-and-outdoor-applications/ 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/ We’ve spoken in the past about the use of our limit switches as Dump Body position detection indicators, but recently this application was highlighted in a dramatically viral way. As Carlos Escobedo and his father were travelling down the East Loop in Houston Texas, they noticed this completely oblivious dump truck driver heading down the highway with the dump body extended in all its glory. Despite attempts by Carlos and other motorists to warn the truck driver, the best Carlos could do is pull out the cell phone to video this extraordinary collision. (WARNING: EXPLICIT LANGUAGE) Watch Video Here The force of this collision was such that it completely flipped the dump truck, and sent pieces of the overhead sign flying all over the highway, endangering motorists and shutting down the entire highway for several hours. Miraculously, no one was killed. The Case for Mandatory Dump Body Detect This is not the first video taken of this kind of incident, and the fact is that thousands of drivers of construction vehicles and bucket trucks make this mistake occasionally, hopefully with less spectacular consequences. Manufactures of work trucks have long been aware of this potential safety hazard and started to add dump body detectionto vehicles years ago to try and prevent such scenarios. CPI waterproof limit switches have been selected for this critical safety function by a number of different vehicle makers over the years owing to the high reliability and durability requirements this application presents. CPI Solution to Dump Body Position Detection Most commonly chosen for this application is a sealed E1 Limit switch like our B9112, housed in a simulated roller spring actuator bracket as shown. This switch is available in either normally open or closed variations. This configuration has a number of properties that really make it ideal for this application.
Other mounting brackets include straight lever mounts, roller lever, and flush mount lever variations to fit into any form factor available. Final Thoughts On Dump Body Detection While dump body detection is not currently required by law, smart work truck manufactures are not risking it. The potential safety issues are too extreme, and the cost of wiring a robust limit switch to a dashboard light is minimal. Plus, CPI has switches already qualified into this application. It’s kind of a no-brainer…(-: Whatever your vehicle safety requirement, the odds are that CPI has a switch that is a perfect, durable fit for it. Contact us today. Original content posted on https://www.cpi-nj.com/blog/dump-body-position-detection-gets-national-attention/ CPI Manufacturers a line of hand actuated pendant switches, that are completely waterproof, and designed for high vibration, high endurance applications in the industrial and military spaces. They are designed and made entirely in the USA.
It’s fair to say, these are not your mother’s pendants… The CPI switch story started over 70 years ago designing waterproof switches for the military back in WWII. That knowledge has evolved in this modern product line which see’s use in a wide variety of applications. Generally speaking, after folks get tired of in-field failures of those cheap offshore made imported switches, they end up at our door. CPI’s deceptively innocent looking pendant switches actually represent decades of switch research, field testing, and manufacturing advances that allow affordable US based mass production with incredible efficiency. These switches come in dozens of electrical configurations, with specifiable endurance ratings and contact parameters. CPI Pendant Switches – Primary Characteristics. Perhaps the most singular characteristic of this product line is simply that it’s really, really hard to break them. They are designed to last under extreme environmental use cases so as to be perfect for mission critical safety applications or operator hand actuated controls.
CPI Pendant Switch Applications The ways our clients have used our switches over the years is as diverse as your imagination.
CPI Pendant Switches are Unique Problem Solvers For Today’s Demands When the run-of-the-mill commercial pendant switches just won’t get the job done, our unique capabilities in waterproof pendant 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.. Original content posted on https://www.cpi-nj.com/blog/heavy-duty-waterproof-pendant-switches/ While there are hundreds of part numbers in our waterproof limit switch line, there’s only a couple basic ideas you need keep straight to understand how it all works.
For the engineers among you, here’s an equation that might help. (Sealed Pendant Switch) + (Mounting Bracket) = Your Ideal Waterproof Switch! CPI’s Sealed Waterproof Pendant Switch Of course then there are a boatload of electrical, temperature, endurance, and ergonomic options you can specify for your basic pendant switch. Likewise there are numerous stainless steel mounting brackets our switches will fit into including lever mount, roller, pipe mount, simulated lever, and of course hundreds of customizable options etc. Some of our clients don’t even opt for a mounting bracket at all, preferring to hand actuate their switch or simply tie wrap it to their cab roll bar, bicycle handle, fishing rod, or whatever other unique application they have. One other option that isn’t spoken about so often is our waterproof panel mount switch option. In this case we not only provide you a panel mount option for your chosen waterproof pendant switch, we provide you the panel too. Waterproof Panel Mount Switches in ActionEnter Loadmaster of Norway Missouri, manufacturers par excellence of refuse collection vehicles (ie. garbage trucks). Loadmaster recently selected such a configuration for their latest fleet of high compaction rear-loaders as shown below: In this application two custom CPI panel mounts were developed that are easily bolted to either the side of the vehicle. Meant to be operated by men with gloved hands, the switches selected allow operators in the rear to signal the driver in the cab when ready to move, or allow the operators to manually advance the compression throttle as a safety feature prior to moving the vehicle. Selected for this was our K1163-501 and K1164-501 Single and Dual Panels respectively, using variations of our high actuation high force pendant switch. High actuation is better for gloved operation and high actuation force insures that the switches wont easily be activated by accident. Panel Mounted Waterproof Pendant Switches for Your EquipmentIf you have a rough duty piece of equipment begging for a reliable waterproof switch, its highly likely we have an off the shelf product that far exceeds the reliability and capability of what you have now. And we can even stick it in a stainless steel waterproof panel for you. Why not make the switch to CPI today? Original content posted on https://www.cpi-nj.com/blog/panel-mount-pendants-keep-the-neighborhood-clean/ 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/ In the world of material handling equipment, operator safety is probably one of the more critical design considerations. With Forklifts and Telehandlers that are moving tons of sheetrock, cinder-block or other materials you don't really want that to land on somebody. Or run them over while you're moving it around. That would be bad.
Switch Applications for Forklifts and TelehandlersThere are a number of safety systems present in Forklifts and Telehandlers for which CPI waterproof switch products often get selected. Since these specialized vehicles often operate outdoors in less than ideal conditions on construction sites, a tough and durable switch is essential to both equipment uptime, and job safety. Neutral Safety Switch The job of a neutral safety switch is to insure that you can't start a vehicle be it an automobile or a forklift, while the vehicle is in gear. If you allowed that, the vehicle could suddenly lurch forward causing instability of payload and injury to anyone standing too close. On a forklift or telehandler, the neutral safety switch is typically screwed into the valve body on top of the transmission. As such it can be subject to the hot temperatures of the transmission block and valve assembly. For this application our J4001 ball switch is often used owing to its highly robust all stainless steel design, and its qualification for extreme electromechanical endurance. At the heart of the J4 is a patented ball carrier design which prevents contaminates such as mud, dirt, ice, sand, dust, etc. from jamming the ball. Furthermore the switches are completely submersible and are unaffected by water, salt spray, humidity, dirt, dust, sand, icing, oil, shock and vibration. Back Up Alarm Switch If you've ever spent any time in a warehouse or on a construction site, you've for sure heard that loud annoying beeping sound whenever a lift moves backwards. That doesn't happen without the engagement of a switch like our E1078 Waterproof Limit Switch. Our switch is mechanically enganged when the lift moves backward and handles the full current load required by most horns, up to 15A rated load available. Stop Switch An emergency stop switch is a staple of the non-automotive vehicular class of equipment providing immediate cessation of power to key drive systems in an emergency. CPI switches like our B2003 Normally Open pushbutton are 100% waterproof solutions that can be mounted in panels or dashboards anywhere on the vehicle. These pendant style switches come in a full assortment of styles to fit any set of engineering requirements. Electrical ratings, pole configuration, current rating, button height and more can be specified. Electromechanical endurance ratings up to 5 million cycles has been achieved. CPI Waterproof Switch Customization CPI solutions for the non-automotive vehicular market are widespread but share a common desire by manufacturers for tough, reliable and long lasting solutions. All our switches are designed and built in the USA and can be customized to your specific needs. Call us today to discuss your application. This content was originally posted at https://www.cpi-nj.com/blog/safety-switches-for-forklifts-and-telehandlers/ |
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