Taken directly from a competitor’s website, is this description of their watertight limit switch “…have internal parts that are protected against splashing or hose-directed water seepage within the limits of the NEMA specified tests for type 4 watertight enclosures. These switches are not sleet or ice-proof.” That’s a lot of words to say, “not really waterproof”. For engineers looking for a small form factor, truly waterproof and can’t-kill-it-with-a-hammer limit switch we offer, well…our whole product line. To break it down lets take a look at the major types of switches and switch configurations we manufacture. Ball and Plunger Limit Switches Our J4 series limit switches come in both a ball and a plunger variation. These have seen use in military vehicles, construction vehicles, emergency and work trucks, even submarines. These switches can be mechanically activated by a transmission sliding into neutral, or a door or hood closing, or a valve opening up and reaching the limit of its travel, or any one of a hundred other applications where size and durability were the primary concerns. Made of all stainless steel with a patented double seal mechanism, these switches are usually the final resort of engineers who don’t want to mess around with safety limit switches who fail in the field. That’s because configurations of our limit switches have been qualified to over one million cycles. Shown here is one of our cab down detect applications for a military transport. These applications can use our J4 plunger switch typically though many make use of our E1 series switches discussed below. E1 Series Limit Switches When you take one of our Santoprene or Neoprene (extended temperature range) sealed momentary or maintained contact pendant switches and combine them with CPI’s custom actuators and bracket mounting options, the result is a broad line of waterproof limit switches that can be readily configured for your specific applications, usually with an off the shelf purchase from one of our distributors. Many combinations of travel parameters, electrical configurations, roller lever or panel mounting configurations as well as our standard high-endurance capabilities are offered as standard products. It’s Easier to say “Heavy Duty” with CPI Limit Switches. Did we mention that our limit switches actually operate underwater? And at -40F or 220F? Here’s how we say that in our product description. “CPI limit switches are waterproof and weatherproof.” Easy right? Original content posted on https://www.cpi-nj.com/blog/a-heavy-duty-limit-switch-with-a-simple-explanation/ 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/ Sometimes, the best engineering advances arise out of failure. To quote Thomas Edison “I have not failed. I’ve just found 10,000 ways that don’t work!” Indeed as one looks at the development history of CPI’s patented J4 ball switch, its current category leading performance did not come without decades of trial and error, and improvement. Perhaps the best way to illustrate this is through the story of our use on one of the military most famous military vehicles of the the last 30 years, the Hummer. In the late 80’s and 90’s the Hummer or Humvee was born. Tipping the scales at 10,000 lbs and getting less than 10 miles per gallon, the military version came to the publics attention when it saw action in the 1989 invasion of Panama, and the first Persian Gulf War. A civilian version of the vehicle dubbed the “Humvee” was first released in 1992 and shot to fame, embraced by celebrities like Arnold Shwartzenegger who went on to own a whole fleet of them! A Technical and Reliability Challenge Even the smaller commercial versions of the Humvee faced some challenges owing to the massive size and power of the transmission and drive train, supporting all that weight under extreme operating conditions. One such problem had to do with the detection of neutral in the transmission, the so-called “neutral-safety” application. Neutral safety refers the need to detect when a vehicle transmission is not in gear. Certain actions in the vehicle are only permitted when the vehicle is in neutral and there is no danger of sudden movement. Detection of neutral is one of the most critical safety systems in a vehicle and is present in almost all modern vehicles, both military, and in regular automobiles. In the Humvee, detection of neutral safety was becoming a big headache for its maker (AM General Corp, and later GM). Qualification requirements for neutral safety required an extremely robust “ball-switch) type design that was waterproof, vibration resistant, could even operate when frozen in ice! It also had to have low profile and extremely high electromechanical endurance over hundreds of thousands of cycles. But when the makers of the HUMVEE came to CPI, nothing they had tried was surviving the qualification requirements. Where Other Switches Fail, The J4 Evolves and Succeeds.While the J4 was already a robust, class leading all stainless steel switch, the requirement to operate when frozen in ice was particularly problematic, as were the mounting considerations for this application. Learning heavily from the failures of many different manufacturers parts, CPI engineers came up with an entirely new (patented) ball carrier that had the potential to solve both the freezing problem, while simultaneously increasing the endurance of the switch. It works as follows: In the new J4 design a “double seal” is employed. As pictured below, this sealing mechanism actually seals the actuator both before, and the second seal, seals it during actuation. Not only does this prevent liquid and small particulates from entering the housing, but upon release any unwanted liquids or particulates that have entered the outer chamber are forced back out of the switch. The seal design has the additional effect of preventing “freeze-up” in the housing by double insulating the contacts from the freezing effects that plagued competitor switches. The J4 ball switch was the only switch Humvee ever tested that was able to operate successfully while completely frozen in ice. After meeting these electrical and operational requirements, CPI further expanded the base product with a variety of mounting threads and lengths for installation into transmissions and ultimately CPI created a variation of the original ball switch design – the J4 plunger switch, which was used in the Military’s cab tilt limit application, where once again, nothing else survived the qualification requirements. When You’re Done Messing Around, Try A Real Waterproof Switch If your application calls for a robust waterproof ball switch or plunger type switch, you won’t find a more durable, or easily mounted, truly waterproof limit switch solution than the CPI J4 series. Samples are available for qualified applications. Please call the factory. Original content posted on https://www.cpi-nj.com/blog/cpis-j4-ball-switch-a-problem-solver-for-the-military-and-beyond/ 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/ 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/ 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/ 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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