Switch having integral remote actuating device

FIELD OF THE INVENTION

This switch broadly relates to an electrical switch having a control arrangement for adjusting the position of a pair of contacts and, more particularly, pertains to a switch which can be easily modified to allow the switch to be remotely actuated while still permitting the switch to be manually operated.

BACKGROUND OF THE INVENTION

Various switching devices are known that include a solenoid or other movable device for adjusting the position of a pair of contacts. One such device is disclosed in U.S. Pat. No. 3,852,658 issued Aug. 27, 1974 to Hayden. In this patent, a manually operated switch has a housing in which a pair of solenoids are permanently mounted. Each of the solenoids has a plunger coupled to a common movable armature. The movement of the armature caused by actuation and deactuation of the solenoids enables contacts on a circuit board attached to the solenoids to be opened and closed.

Hayden is representative of several electrical switch component configurations wherein the solenoids or other remote actuators are fixed within the electric switching component housing so that they cannot be modified, replaced, or reengineered. In the event of a problem with such a switch, a common remedy is to replace the entire switch which may not be the most efficient method of resolving the problem. For example, even though the mechanical aspects of the switch may be in good working order, failure of one or more of the solenoids or their internally mounted circuit or control arrangement causes installation of an entirely new switch which may be unnecessarily expensive for the switch user.

Accordingly, it is desirable to provide a manually operable switch design so that it can be remotely actuated from outside the switch housing. It is also desirable to provide a manually operated switch with a remote actuation feature which can be added to the switch at any time. It is further desirable that the remote actuation be provided by various force generating devices not necessarily limited to a solenoid.

SUMMARY OF THE INVENTION

It is a general object of the present invention to provide a manually operated switch which may be conveniently and economically converted to a remotely actuated device.

It is also an object of the present invention to provide a switch housing designed to transfer motion to a switch handle from outside the switch housing.

It is a further object of the present invention to provide a switch housing which is simply modified to accept a remote actuation device without disassembly of the switch housing.

It is an additional object of the present invention to provide a manually operable switch for selectively accepting a pair of plungers in order to transfer movement from a force generating device to the handle of the switch.

It is another object of the present invention to provide a manually operated switch having an optional remote actuation feature which may be installed without special tools or fasteners.

In one aspect of the invention, a manually operable switch has an operating handle movably mounted on a housing for moving a set of contacts in the housing from one position to another. The invention is improved by a force generating arrangement mounted outside the switch housing, and a force translation system extending between the housing and the force generating arrangement. The force translation system has a first end structure movable into and out of contact with the operating handle and a second end structure disposed for movement in the force generating arrangement. The force generating arrangement is selected from the group consisting of an electromagnetic solenoid, a wax motor, a linear actuator, a shape memory effect (SME) actuator, a servo motor, a stepper motor, a pneumatic cylinder, a hydraulic cylinder and a piezoceramic actuator. The preferred embodiment has a forced translation system comprised of a pair of elongated plungers. A control structure is operably connected to the force generating device outside the housing.

In another aspect of the invention, a switch includes a housing having wall structure formed with at least one throughbore, and an operating handle pivotally mounted to the wall structure for manually moving a set of contracts in the housing from one position to another. A force generating device is disposed externally of the housing. At least one plunger is movably mounted in the throughbore and has one end engageable with the operating handle and an opposite end engageable with the force generating device. A housing has a lower section removably attached to an upper section. A wall structure of the housing lower section has a length and a height, the throughbore being formed along substantially the entire height of the wall structure of the housing lower section. The housing is suspendedly mounted in a support panel.

In yet another aspect of the invention, a manually operable switch is provided which is remotely actuated. The switch includes a housing mounted in a support panel and having wall structure formed of a pair of spaced apart throughbores, and an operating handle with opposed ends pivotally mounted to the wall structure for moving a set of contacts from one position to another, the opposed ends of the operating handle being aligned with the throughbores. A pair of force generating devices is mounted exteriorly of the housing on a support structure. A pair of elongated plungers is disposed for reciprocal movement in the throughbores, each plunger having a first end movable into and out of contact with one end of the operating handle and a second end disposed for movement in one of the force generating devices. A control structure is disposed outside the housing and is operably connected to the force generating devices to control actuation and de-actuation thereof so as to move the plunger in a manner which will remotely pivot the operating handle. The force generating devices are located beneath the housing. The control structure is comprised of a controller, a receiver and a transmitter, all interconnected together.

The invention also contemplates a method of converting a manually operable switch to a remotely actuated switch, the switch having an operating handle movably mounted on a housing for moving a set of contacts from one position to another. The method includes the steps of forming a housing with a pair of throughbores in alignment with opposite ends of the operating handle; providing a pair of force generating devices mounted outside the housing, each of the force generating devices having a plunger movably mounted therein with a first end receivable in one of the throughbores and movable into and out of engagement with an end of the operating handle, and a second end disposed for movement in the force generating device; inserting the plungers into the throughbores in the housing; and selectively actuating the force generating devices so as to effect remote movement of the operating handle.

Various other objects, features and advantages of the invention will be made apparent from the following description taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate the best mode presently contemplated of carrying out the invention.

In the drawings:

FIG. 1

is a perspective view of a switch embodying an optional remote actuating arrangement of the invention;

FIG. 2

is an enlarged sectional view taken on line

2

—

2

of

FIG. 1

;

FIG. 3

is an enlarged sectional view taken on line

3

—

3

of

FIG. 2

;

FIG. 4

is a view similar to

FIG. 3

showing a control system for remotely moving the switch to one operating position; and

FIG. 5

is a view similar to

FIG. 4

showing a control system for remotely moving the switch to an opposite operating position.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings,

FIG. 1

illustrates a planar support panel

10

formed with a suitable opening for seating a manually operable switch

12

having stabilizing protrusions

14

as seen in FIG.

3

and described in assignee's pending U.S. patent application Ser. No. 10/037,387 filed Jan. 4, 2002, now U.S. Pat. No. 6,613,995, which is hereby incorporated by reference. Switch

12

, as will be discussed below, is provided with a remote actuation feature which is extremely useful in situations where the switch

12

is inaccessible or otherwise unable to be manually operated.

Switch

12

is preferably a single pole, double throw (SPDT) paddle switch having a generally rectangular housing

16

with a periphery which is slightly smaller than the support panel opening. In the preferred embodiment housing

16

has an upper section

18

removably attached to a lower section

20

.

Upper section

18

has four corners and a top facing

22

which has flanges

24

extending outwardly therefrom for overlying engagement with the support panel

10

to prevent the switch

12

from sliding through the panel opening. As seen in

FIG. 3

, the upper section

18

is open along its top to receive a movable operating handle

26

having opposed ends

28

,

30

and a central spine

32

which is pivotally mounted at

34

to opposite sides of the upper section

18

. The spine

32

terminates in a pair of cylindrical receivers

36

(one being seen in the drawings) for slidably accommodating a pair of fingers

38

(one being shown in the drawings). Each of the fingers

38

is biased outwardly by a compression spring

40

for engagement with a movable contact structure in the lower section

20

. Opposite ends of upper section

18

are provided with downwardly depending resilient legs

42

having hooked bottoms

44

adapted to snap into ends of lower section

20

. The bottom of upper section

18

has a pair of transverse walls

46

, one being between each leg

42

and the receivers

36

to add reinforcement to the upper section

18

.

Lower section

20

, as shown in

FIGS. 2 and 3

, also has four corners defined by the intersection of opposed side walls

48

,

50

and opposed end walls

52

,

54

. As will be appreciated hereafter, the end walls

52

,

54

are formed thicker than the side walls

48

,

50

so that a pair of throughbores

56

,

58

extend throughout the height of the lower section

20

. One of the throughbores

56

is located at a rear corner on one side of the lower section

20

, and the other of the throughbores

58

is formed at a front corner on the other side of the lower section

20

. These throughbores

56

,

58

are utilized to facilitate a simple conversion of the manually operable switch

12

to a remotely actuated switch.

Lower section

20

has an open top for receiving a V-shaped contact plate

16

which is rocked back and forth by motion of the pivoting operating handle

26

. The contact plate

60

has a pair of movable contacts

62

,

64

at opposite ends which are selectively engageable with fixed contacts

66

,

68

mounted at opposite ends on an inside bottom wall

70

of the lower section

20

. Each fixed contact

66

,

68

is provided with a conducting terminal bracket

72

,

74

which depends from the bottom wall

70

. Contact plate

60

has an apex

76

with a top surface engaged by the spring biased fingers

38

, and a bottom surface which pivots on top of a fixed grounding contact

78

. Grounding contact

78

is connected to a grounding terminal bracket.

80

which depends from the bottom wall

70

on one side of the lower section

20

between the conducting terminal brackets

72

,

74

. The inside bottom wall

70

also includes two pairs of transverse ridges

82

,

84

for strengthening bottom wall

70

and maintaining the separation of the contacts

66

,

68

. The inner pair of ridges

82

extends partially upwardly along the inside surfaces of the side walls

48

,

50

to provide a guiding channel into which opposed projections on the apex

76

of V-shaped contact plate

60

are disposed. Opposite end walls

52

,

54

of the lower section

20

include notches

86

into which the hooked bottoms

44

of the upper section legs

42

are retained when the upper section

18

is pushed downwardly into the lower section

20

to complete the switch

12

.

In

FIGS. 1 and 3

, the assembled and seated, manually operable switch

12

is shown in a neutral position in which the operating handle

26

is centered so that the spine

32

is vertical and both movable contacts

62

,

64

are spaced apart from their mating fixed contacts

66

,

68

. In

FIG. 4

, the operating handle

26

is manually moved to the left in the direction of the upper arrow so as to flip the contact plate

60

causing contacts

64

,

68

to engage and define, for example, an ON position.

FIG. 5

shows the operating handle

26

manually moved to the right as indicated by the upper arrow so as to move the switch

12

, for example, to an OFF position.

In accordance with the present invention, the manually operable switch

12

may be conveniently and economically converted as an option to a remotely actuated switch. That is, switch

12

can be modified to include a force generating arrangement mounted outside the switch housing, and a force translation system extending between the housing

16

and force generating arrangement. The force translation system has a first end structure movable into and out of contact with the operating handle

26

, and a second end structure disposed for movement in the force generating arrangement. Control structure is operably connected to the force generating arrangement outside the housing

16

to control actuation and deactuation thereof.

Force generating arrangement preferably takes the form of a pair of spaced is apart, electromagnetic linear solenoids

88

,

90

which are fixed or removably mounted on a support structure

92

exteriorly of and beneath the switch housing

16

. At this point, it should be understood that the force generating arrangement may also suitably take the form of an electromagnetic rotary solenoid, a wax motor, a linear actuator, a shape memory effect (SME) actuator, a servo motor, a stepper motor, a pneumatic or hydraulic cylinder or a piezoceranic actuator.

Force translation system is defined preferably by a pair of elongated plungers

94

,

96

, each being slidably received for linear up and down movement in a respective cavity

98

,

99

of a respective solenoid

88

,

90

. Solenoids

88

,

90

and their plungers

94

,

96

are strategically placed on support structure

92

at diagonally opposite corners beneath housing

16

such that the plungers

94

,

96

are in alignment with the throughbores

56

,

58

formed in the corner wall structure of the switch housing

16

. Each plunger

94

,

96

has a respective upper end

102

,

104

which is movable into and out of engagement with a respective opposed end

28

,

30

on the operating handle

26

, and a respective lower end

106

,

108

movable up and down in the respective solenoid cavity

98

,

99

.

Referring now to

FIGS. 4 and 5

, control structure is preferably comprised of a controller

110

operably connected to the solenoids

88

,

90

, a receiver

112

operably connected to the controller

110

for sending a control signal thereto, and a transmitter

114

operably connected to the receiver

112

to transmit the control signal causing the switch

12

to remotely rather than manually assume an ON or OFF position.

In

FIG. 4

, the control actuates only solenoid

90

so that plunger

96

will move in the direction of the lower arrow upwardly and contact the right-hand end

30

of operating handle

26

so that handle will pivot to the left. As described in the manual operation, this motion causes engagement between contacts

64

,

68

so as to provide a first or ON position. When it is desired to move the switch

12

to a second or OFF position, solenoid

90

is deactuated so plunger

94

will move upwardly as shown in

FIG. 5

by the lower arrow and abut the opposite end

28

of the operating handle

26

. This will pivot the operating handle

26

in the opposite direction as

FIG. 4

so that engagement between contacts

62

,

66

is made. If necessary, both plungers

94

,

96

can be simultaneously controlled by the solenoids

88

,

90

to place the operating handle

26

in a neutral position of FIG.

3

.

It must be appreciated that in order to convert the manually operable switch

12

to a remote actuated switch, one simply slides the upper ends

102

,

104

of the plungers

94

,

96

into the throughbores,

56

,

58

from the bottom of the housing

16

. As seen in

FIG. 3

, the plungers

94

,

96

have a length such that their upper ends

102

,

104

extend up to the top of lower section

20

of housing

16

when the lower ends

106

,

108

of the plungers

94

,

96

are completely seated in the solenoids

88

,

90

. There is no need to resort to any insulation tools or fasteners.

It should also be understood that the remote actuated arrangement can be added to or removed from the manually operable switch

12

at any time within a matter of seconds. Likewise, it should be further understood that the force generating arrangement may take many alternative forms other than solenoids

88

,

90

as noted above.

One of the major advantages of the remote actuated switch is that solenoids

88

,

90

and the plungers

94

,

96

are supported exteriorly of the switch housing

16

. This allows an easier and more convenient replacement or reengineering of a switch

12

. The snap assembly of the switch housings

18

,

20

contributes to the efficiency of the switch repair and/or inspection. In prior art remote actuated switches having solenoids permanently fixed inside the housing, it is often the case that entire switches are discarded in lieu of entire new switches which adds to the operating cost to the user. It is also important to note that the solenoids

88

,

90

or other actuators can be remotely mounted to their support structure

92

so that they can be easily replaced without having to disassemble the switch

12

.

While the switch

12

described above shows the preferred use of two solenoids and two plungers, it is within the purview of the invention that a user might design a switch having a spring biased operating handle and a single plunger and solenoid combination. In such design, the operating handle could be biased to one position and the plunger and solenoid could be used to temporarily move the switch to another position.

While the invention has been described with reference to a preferred embodiment, those skilled in the art will appreciate that certain substitutions, alterations and omissions be made without departing from the spirit thereof. Accordingly, the foregoing description is meant to be exemplary only, and should not be deemed limitative on the scope of the invention as set forth in the following claims.