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/ 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/ For the team here at CPI it’s been an exciting 2018. After a long period where companies large and small were discouraging capital investment, its safe to say that the military-industrial complex had largely recovered by 2018. We saw renewed investments in product development and design, and increased willingness by manufacturers of industrial equipment, to upgrade and expand their product offerings.
As a supplier of premier waterproof switches and unique linear position sensors, the good economic news has certainly trickled down into our supply chain. While our product line is diverse, we’ve seen an almost across the board uptick in design-ins across industries. in industry’s like oil and gas, we’ve seen renewed interest in our extreme duty linear position sensors. Our limit switches saw major design in’s Construction Vehicles, and military applications. And our thermal switches continue to find applications both inside and outside the military where only a reliable thermal switch will do. Here’s a few Highlights:
We continue to be amazed at the diversity of applications that our switches and sensors find themselves in. It seems that when you need a no-holds-barred solution to robust waterproof switching, there are actually very few good choices in the world…(-: Onward and Upward We want to thank all our customers in 2018 for continuing to support our USA made products and continuing to recognize the unique value and no compromises engineered products that we offer. And if you’re new to CPI, welcome. We look forward to new and interesting partnerships in 2019. Sincerely, Mac Stuhler Original content posted on https://www.cpi-nj.com/blog/make-the-switch-to-cpi-in-2019/ 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/ In the USA, having basic appliances with which to store food, like a refrigerator, is mostly taken for granted. In developing nations however, this is not the case. Globally, tons upon tons of food is lost each year, and a lack of refrigeration plays a part in this. Some sources say that one third of food produced today will end up being lost for one reason or another. Others say that around 40 percent of food is lost before it reaches markets. Either way, the number stands around 1.3 billion tons a year.
Now imagine a world where cooked food products can be sealed in plastic and stored in a cabinet, a box in your garage, or a hole in your backyard. Imagine you can open them years later, and they taste every bit as though they were just made fresh even though they were stored unrefrigerated and without the addition of any preservatives or chemicals. Imagine a world where foodstuffs like this can now be shipped all over the world on unrefrigerated cargo containers and people would no longer need refrigeration to store “perishable” food. Think of the implications of this for cutting down on waste, eliminating the billions of tons of food that is thrown out every year, for improving the nutrition of the poor in impoverished areas of the world, and cutting costs of food shipping and distribution worldwide. There would be new markets for these trade goods around the world, and potentially even a positive environmental impact. Kind of mind blowing, isn’t it? This is the promise of groundbreaking technology in food manufacturing, distribution, and processing that CPI waterproof switches were recently designed into according to Bill Gillette, Principal of Edge Engineering in Tennessee, a consulting design firm working to help the equipment manufacturer finalize the product. Called the “Microwave Assisted Thermal Sterilization” (MATS), this mechanical food processing system for high volume manufacturing, uses advanced microwave technology. Pre-sealed, uncooked food products are sent along a conveyer belt through various chambers in the machine, exposing the food to specific profiles of microwave generated heat, while under high pressure and submerged completely in water. The food is actually cooked by the machine as conveyers and robotics move the product along. The process also kills 100% of bacteria and virus’ which would normally cause food contamination. All without the addition of any chemical additives. “We need to know when the food carriers are at the end of the processing chambers so that certain robotics can be activated to move them to the next chamber,” says Bill. “In the original solution the manufacturer designed, they chose a complex series of mechanical wheels and cams that would sense and report the position of the tray. It was the only solution they found that could withstand the heat, pressure, and wet environment reliably. The cost of this system alone was close to 10K and each machine needed 6 of them.” When Bill looked at this system, he really felt there had to be a better way. Some Google searches turned up CPI’s line of waterproof switches and the more Bill read, the more excited he became. According to Bill, “CPI seems to be the only company in the world producing switches and sensors whose specs actually meet or exceed our triple threat environment of underwater operation, high temperature environment and operation under extreme pressure.” Chosen for the task was CPI’s E1283-B2002SE simulated roller switch. This is an extended lifecycle version of our standard switch, qualified to 5 million cycles of electromechanical endurance. For the MATS application, knowing that the CPI switch would be fully submerged in water while operating, CPI specified the SE version which stands for “Soft Touch, Extended Life”. In this version of the switch, the neoprene seal over the switch is continuously molded to the wire insulation providing a completely uninterrupted seal all the way to the end of the wire. For MATS, the manufacturer wanted an extremely long lead length of 12 feet or more as well. CPI can make your switch with any custom lead length you require to eliminate splicing. Perhaps the best news for Bill and his client however was the cost savings inherent in the redesign. Instead of 6 complex mechanical position sensing systems contributing almost $60,000 to the cost of the system, 6 CPI E1 series switches were used to create an improved detection system that entirely replaced the original. Because the CPI system was so cost effective, Bill’s team used 9 at a fraction of the original cost of this sensor subsystem. Original content posted on https://www.cpi-nj.com/blog/groundbreaking-food-storage-machines-use-cpi-switches/ 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/ 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 broad category of “Work Trucks” or “vocational trucks” includes vehicles from ambulances to class 8 heavy trucks weighing over 33,000 pounds . Unlike cars and your consumer oriented pickup truck, these vehicles really work for a living, and are built for a complex purpose beyond getting you from here to there.
As a manufacturer of some of the worlds most durable and reliable waterproof safety switches, CPI brings both deep and broad experience to the problems of safety system designers for work trucks. The CPI switches and sensors designed into these trucks of every type represent a small, but critically important component of overall safety system operation. Chances are no matter what safety system your vocational truck design needs, you won’t be blazing any new trails by designing in CPI hardened limit switches and ball switches. Work Truck Applications for CPI Waterproof Switches Here are some examples: Emergency Vehicles – Often use our E1 limit switches for Outrigger Deployment detection to insure the stabilizer is locked into place. Bucket Trucks – Bucket truck manufacturers have used a wide variety of our E1 limit switches as part of safety systems controlling the boom hydraulics and buckets. Our control panels have been used to provide operator control through our panel mounted waterproof pendant switches. Agricultural Sprayers – Use our J4 ball switch to sense that sprayer arms are locked owing to its ability to withstand highly corrosive spray fertilizers. 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. 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. Forklifts and Construction Vehicles – Our operator controlled, Waterproof Pendant Switches are the perfect solutions to things like backup alarms and siren control. Or put this in any of dozens of mounting brackets we can provide and let the machine activate it. Our K1005 using our E1057 mounting bracket is a great example of this. Military Vehicles – In applications like Door Alarms, and Neutral Safety detection, our J4 ball switch has been designed into tough vehicles for its durability, reliability, and small form factor. Vocational Vehicles Need More Reliable PartsOn 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/safety-systems-on-work-trucks/ Emergency vehicles like ambulances, law enforcement vehicles, police cars and motorcycles, and fire trucks represent some very specially designed vehicles. Packed with special equipment, and special usability requirements, these vehicles are equipped with safety systems and fail safe systems way beyond what would be needed in your average family sedan.
Because of the critical and specialized nature of the work done by first responders, one might say that “failure is not an option”. Imagine an ambulance that accidentally speeds away without the door being fully closed…or a helmet microphone that fails during a critical police motorcycle chase. Or a fire truck that becomes unstable at the scene because outriggers were not set properly. These, and dozens of other safety systems on emergency vehicles rely on CPI switches to be there every day, under all conditions. Ambulance Door Switch – Emergency Unlock One great example of an emergency vehicle application is the use of our E1005-B7151 waterproof limit switch as a hidden ambulance door open switch. Used by several ambulance manufacturers like Braun and PL Custom, these hidden waterproof switches allow operators into the vehicles when keys are not available to open the door. (You know, like when someone locks them in the ambulance…) Our switch Is mounted by manufacturers in a “hidden” area that is known only to the ambulance operators and allows them quick access in an emergency. For obvious reasons we can’t divulge exactly where the switches are mounted but suffice to say that our B7151 waterproof switch was chosen due to its ability to withstand the elements including water and vibration, as well as its extremely high electromechanical endurance. This switch has been qualified to over 5 million cycles without failure, with variations that can handle current up to 20A (at lower endurance ratings). Our basic B7151 switch is an industrial grade sealed pendant-style switch. It is normally open and features a high pushbutton, low actuation force configuration. The variation above is mounted in our stainless steel E1005 surface bracket. The leads are sealed into the switch at the factory and can be delivered in any length required by your application. Delivering Robust Switches And Sensors to Emergency Vehicles and Beyond While just one example, our switches actually provide numerous points of interface with man and machinery in the emergency vehicle safety system space. We usually get the call when manufacturers and integrators need a truly reliable, field proven, and USA made solution. You know, when failure is not an option. Call CPI’s Waterproof Switch team today to discuss your application. Original content posted on https://www.cpi-nj.com/blog/first-responders-rely-on-cpi-switches/ 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/ |
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