Patent Publication Number: US-6714106-B1

Title: Switch having integral remote actuating device

Description:
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&#39;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.