Adaptable rotary power control switch

• US 4,724,286 A
• Filed: 07/01/1986
• Issued: 02/09/1988
• Est. Priority Date: 07/01/1986
• Status: Expired due to Term

• Current Assignee: Power Controls Corporation
• Original Assignee: Power Controls Corporation
• Inventors: Cummins, James P.
• Primary Examiner(s): Scott, J. R.
• Application Number:
  US06/881,127
• Time in Patent Office: 588 Days
• Field of Search: 200/1 R, 200/5 R, 200/4, 200/6 R, 200/6 B, 200/7, 200/11 R, 200/11 J, 200/11 D, 200/11 DA, 200/11 G, 200/11 K, 200/11 E, 200/11 EA, 200/14, 200/17 R, 200/18 , 200/153 J, 200/153 L, 200/293, 200/329, 200/336, 200/337, 174/16 HS, 338/200, 338/215
• US Class Current: 200/4
• CPC Class Codes: H01H 11/0018 for allowing different operating parts
• CPC Class Codes: H01H 13/58 with contact-driving member rotated step-wise in one direction
• CPC Class Codes: H01H 19/62 Contacts actuated by radial cams
• CPC Class Codes: H01H 3/0213 Combined operation of electric switch and variable impedance, e.g. resistor, capacitor H01H9/061 takes precedence

Abstract

A rotary power control unit is capable of functioning as many different switches. The power control unit includes a housing, a shaft-actuator assembly, a circuit board with a variable resistor, and a strap for containing these elements in the housing. The shaft-actuator assembly is rotatably attached to the floor of the housing, and passes through the circuit board and strap where it is connected to a control knob. The shaft is also fastened to a wiper shoe which rotates with the shaft and varies the resistance of the circuit. By interchanging shaft-actuator assemblies, and adding appropriate components to the circuit board, the rotary power control unit may take the form of:

a simple rotary control,

a rotary control with full-on bypass,

a simple push control,

a three-way push control, or

a tandem push control.

Claims

1. An adaptable rotary power control switch comprising:

a switch housing having an open side, an interior floor and side walls;

an anchor means with a cylindrical bore therein for rotatably attaching a chosen one of a variety of shaftactuator assemblies with upper and lower portions to said interior floor said lower portions dimensioned to slidably fit into said cylindrical bore in said anchor means;

a power-limiting circuit board for receiving electrical components in differing arrangements, having an aperture for passage of said upper portion of said chosen shaft-actuator assembly;

contact means activated by rotation of said chosen shaft-actuator assembly causing electricity to flow from a power source through said circuit board;

wiper means operated by said shaft-actuator assembly whereby rotation of said chosen shaft-actuator assembly affects first variable resistance means, said first variable resistance means being integral with said circuit board; and

a planar strap having top and bottom sides for retaining said chosen shaft-actuator assembly, said circuit board, and said wiper means within said switch housing, said strap covering said open side of said switch housing, and having a first aperture for passage of said upper portion of said chosen shaft-actuator assembly.

2. An adaptable rotary power control switch as recited in claim 1, said contact means further comprising:

at least one armature with a first and a second end for electrical connection at said first end to said power source;

a contact tab electrically connected to said circuit board; and

said armature being movable by said chosen shaft-actuator assembly whereby said second end of said armature is electrically coupled to said contact tab allowing electricity to flow therethrough and energizing said circuit board thereby.

3. An adaptable rotary power control switch as recited in claim 2, said switch housing comprising:

support means mounted on said side walls for supporting said circuit board;

attachment means for securing said strap to said switch housing;

peg means for attachment of at least one of said armatures to said switch housing; and

said switch housing having an exit aperture for power supply wires.

4. An adaptable rotary power control switch as recited in claim 3, said wiper means comprising:

a circular wiper shoe with a top surface and bottom surface having a central aperture and an inwardly extending sprocket for axial connection with said chosen shaft-actuator assembly, said wiper shoe also having an annular depression and a radial rib on said top surface, and having an annular depression and rectangular seat on said bottom surface, said wiper shoe parallel to and located in between said circuit board and said strap;

a first wiper having dual contacts, said first wiper located in said rectangular seat of said wiper shoe, said dual contacts slidably urged against said first variable resistance means; and

a stop peg mounted on said bottom side of said strap for limiting rotational movement of said wiper shoe by forcible contact with said radial rib, said forcible contact occurring at an acute rotational position of said wiper shoe and at an obtuse rotational position of said wiper shoe.

5. An adaptable rotary power control switch as recited in claim 4, said anchor means comprising:

a spline cylinder attached and perpendicular to said interior floor for mating with said lower portion of said chosen shaft-actuator assembly; and

a lower reset gear attached to said interior floor and surrounding said spline cylinder.

6. An adaptable rotary power control switch as recited in claim 5 further comprising:

a U-shaped wiper shell having top and bottom surfaces, located adjacent to said wiper shoe, rotatably fastened to said circuit board, said wiper shell having a central slotted advancing bolt accessible through a second aperture of said strap, and having on said bottom surface an annular depression and a rectangular seat; and

a second wiper having dual contacts, said second wiper located in said rectangular seat of said wiper shell, said dual contacts slidably urged against second variable resistance means, said second variable resistance means being integral with said circuit board.

7. An adaptable rotary power control switch as recited in claim 1, said anchor means comprising:

a spline cylinder attached and perpendicular to said interior floor of said switch housing for mating with said lower portion of said chosen shaftactuator assembly; and

a lower reset gear attached to said interior floor and surrounding said spline cylinder.

8. An adaptable rotary power control switch as recited in claim 7 wherein said chosen shaft-actuator assembly is a simple push control comprising:

a shaft having a longitudinal groove for mating with said wiper means, said shaft having at one end a flange integral which tapers away from said shaft ending in an alignment pin;

a circular indexing gear having upper and lower ends, said upper end having a concave seat and aperture for mating with said tapered flange and alignment pin, said lower end having upper indexing teeth, and having a central spline shaft for mating with said spline cylinder of said anchor means;

a hollow, cylindrical push actuator with upper and lower ends having therein lower indexing teeth for meshing with said upper indexing teeth, said push actuator having upper lobes on the outer surface thereof for pushing said contact means, and having at said lower end an upper reset gear for meshing with said lower reset gear of said anchor means; and

a spring for displacing said indexing gear away from said push actuator.

9. An adaptable rotary power control switch as recited in claim 7 wherein said contact means comprises a first armature and a second armature, and wherein said chosen shaft-actuator assembly is a three-way push control comprising:

a shaft having a longitudinal groove for mating with said wiper means, said shaft having at one end a flange integral therewith which tapers away from said shaft ending in an alignment pin;

a circular indexing gear having upper and lower ends, said upper end having a concave seat and aperture for mating with said tapered flange and alignment pin, said lower end having upper indexing teeth, and having a central spline shaft for mating with said spline cylinder of said anchor means;

a hollow, cylindrical push actuator with upper and lower ends having therein lower indexing teeth for meshing with said upper indexing teeth, said push actuator having upper lobes on the outer surface thereof for pushing said first armature and having lower lobes on the outer surface thereof for pushing said second armature, said lower lobes placed out of phase with said upper lobes, said push actuator also having at said lower end an upper reset gear for meshing with said lower reset gear of said anchor means; and

a spring for displacing said indexing gear away from said push actuator.

10. An adaptable rotary power control switch as recited in claim 7 wherein said contact means comprises a first armature and a second armature, and wherein said chosen shaft-actuator assembly is a tandem push control comprising:

a shaft having a longitudinal groove for mating with said wiper means, said shaft having at one end a flange integral therewith which tapers away from said shaft ending in an alignment pin;

a circular indexing gear having upper and lower ends, said upper end having a concave seat and aperture for mating with said tapered flange and alignment pin, said lower end having upper indexing teeth, and having a central spline shaft for mating with said spline cylinder of said anchor means;

a hollow, cylindrical push actuator with upper and lower ends having therein lower indexing teeth for meshing with said upper indexing teeth, said push actuator having upper lobes on the outer surface thereof for pushing said first armature and having lower lobes on the outer surface thereof for pushing said second armature, the cyclical rotational progression of such upper and lower lobes being (i) upper lobe only, (ii) lower lobe body, (iii) both upper and lower lobes, and (iv) neither upper now lower lobes, said push actuator also having at said lower end an upper reset gear for meshing with said lower reset gear of said anchor means; and

a spring for displacing said indexing gear away from said push actuator.

11. An adaptable rotary power control switch as recited in claim 1 whreein said chosen shaft-actuator assembly is a simple rotary control comprising:

a shaft with upper and lower portions, said shaft having a longitudinal groove in said upper portion for mating with said wiper means;

a flange integral with said shaft located near the center of said shaft; and

a first simple actuator integral with said shaft located between said flange and said lower portion of said shaft, said first simple actuator placed at an appropriate angle with respect to said longitudinal groove whereby said first simple actuator pushes against said contact means when said wiper means is rotated to an acute rotational position.

12. An adaptable rotary power control switch as recited in claim 1 wherein said contact means comprises a first armature and a second armature, and wherein said chosen shaft-actuator assembly is a rotary control with full-on bypass comprising:

a shaft with upper and lower portions, said shaft having a longitudinal groove in said upper portion for mating with said wiper means;

a flange integral with said shaft located near the center of said shaft; and

a first simple actuator integral with said shaft located between said flange and said lower portion of said shaft, said first simple actuator placed at an appropriate angle with respect to said longitudinal groove whereby said first simple actuator pushes against said first armature when said wiper means is rotated to an acute rotational position, and said first simple actuator having a mortise therein; and

a circular bypass actuator having upper and lower tiers and having a central aperture for passage of said lower portion of said shaft, said upper tier having a smaller diameter than said lower tier, said upper tier having integral thereto a tenon for alignment with said mortise, said lower tier having a concavity along its edge, said concavity placed at an appropriate angle with respect to said tenon whereby said concavity receives said second armature when said wiper means is rotated to an obtuse rotational position.

13. An adaptable rotary power control switch as recited in claim 1 wherein said contact means comprises a first armature and a second armature, and wherein said chosen shaft-actuator assembly is a three-way rotary control comprising:

a shaft with upper and lower portions, said shaft having a longitudinal groove in said upper portion for mating with said wiper means;

a flange integral with said shaft located near the center of said shaft;

a first simple actuator integral with said shaft located between said flange and said lower portion of said shaft, said first simple actuator placed at an appropriate angle with respect to said longitudinal groove whereby said first simple actuator pushes against said first armature when said wiper means is rotated to an acute rotational position; and

a second simple actuator integral with said shaft located between said first simple actuator and said lower portion of said shaft, said second simple actuator placed at an appropriate angle with respect to said first simple actuator whereby said second simple actuator pushes said second armature when said wiper means is rotated to an obtuse rotational position.

14. A family of power control switches having rotary motion for variable control of an electronic circuit, said family of said power control switches comprising:

a switch housing having an open side;

rotary shaft means rotatably anchored on a first end inside said switch housing, a second end of said rotary shaft means extending out said open side of said switching housing;

a circuit board having most of said electronic circuit thereon resting on abutting means inside said switch housing, said circuit board being generally parallel to said open side of said switch housing;

wiper means carried by said rotary shaft means for electrically contacting variable resistance means of said electronic circuit to give variable resistance as said rotary shaft means rotates, said variable resistance means being on said circuit board;

strap means covering said open side of said switch housing, said strap means having an opening for said second end of said rotary shaft means to extend therethrough said strap means continually urging said wiper means against said circuit board for electrically contacting said variable resistance means by said wiper means and holding said circuit board against said abutting means, said rotary shaft means having a flange larger than said opening in said strap means, said strap means providing a heat sink for said electronic circuit;

contact means connected to said circuit board; and

armature means actuated by initial rotary motion of said rotary shaft means to electrically connect through said contact means to allow said variable control by said electronic circuit.

15. A family of power control switches as recited in claim 14, said switch housing comprising:

an interior floor and four side walls;

attachment means for securing said strap means to said switch housing;

peg means for attachment of said armature means to said switch housing;

anchor means for rotatably attaching said first end of said rotary shaft means to said switch housing; and

said switch housing having at least one exit hole for power supply wires.

16. A family of power control switches as recited in claim 15, said anchor means comprising:

a spline cylinder integral with and perpendicular to said interior floor of said switch housing; and

a reset gear integral with said interior floor of said switch housing and surrounding said spline cylinder.

17. A switch housing for containing mechanical and electrical elements of a power control switch, said switch housing comprising:

a floor with an interior surface;

four side walls integral with and perpendicular to said interior surface;

a spline cylinder attached and perpendicular to said interior surface of said floor; and

a reset gear attached to said interior surface to said floor and surrounding said spline cylinder.

18. A switch housing as recited in claim 17 further comprising:

a plurality of pegs for attaching an armature to said switch housing; and

a peg surface parallel to and raised above said interior surface of said floor, said pegs mounted perpendicular to said peg surface.

19. A switch housing as recited in claim 18 further comprising:

a plurality of support members perpendicular to said floor and integral with said side walls, for supporting a planar board;

at least one tab integral with one of said side walls extending away from the center of said switch housing, for securing a strap to cover said switch housing and for mounting said switch housing to an exteral surface; and

said switch housing having an exit hole for power supply wires.

20. A push-push actuator for advancing any rotor mechanism, comprising:

a fixed spline cylinder having upper and lower portions;

a lower reset gear integral with and surrounding said lower portion of said spline cylinder;

a hollow, cylindrical rotor having an upper end and a lower end, and having at said lower end an upper reset gear for meshing with said lower reset gear, said rotor surrounding said spline cylinder;

a circular indexing gear for indexing said rotor, having upper and lower ends, and having a central spline shaft for mating with said spline cylinder;

a spring for displacing said indexing gear away from said push-push actuator; and

a control shaft for actuating said indexing gear.

21. A push-push actuator as recited in claim 20 wherein:

said control shaft has at one end a flange integral therewith which tapers away from said control shaft ending in an alignment pin;

said indexing gear has at said upper end a concave seat and aperture for mating with said tapered flange and alignment pin, and said indexing gear also has at said lower end upper indexing teeth; and

said rotor has therein lower indexing teeth for meshing with said upper indexing teeth.

22. A power control switch kit capable of being assembled with any one of a chosen variety of shaft-actuator assemblies comprising:

a chosen one of said variety of shaft-actuator assemblies having upper and lower portions;

a switch housing, said switch housing comprising a floor with an interior surface, side walls, and anchor means attached to said interior surface adapted to receive said lower portion of said chosen one of said variety of shaft-actuator assemblies when said kit is assembled;

a circuit board adapted to be fitted inside said switch housing, said circuit board having an aperture adapted to allow passage of said upper portion of said chosen one of said variety of shaft-actuator assemblies, when said kit is assembled, said circuit board further having a contact means attached thereto whereby when said kit is assembled rotation of said one of said variety of shaft-actuator assemblies and said contact means cause electricity to flow from a power source through circuitry of said circuit board;

a wiper shoe adapted to be positioned adjacent to said circuit board, said wiper shoe having an aperture adapted to allow passage of said upper portion of said chosen one of said variety of shaft-actuator assemblies and having a wiper member engaging conductive paths on said circuit board when said kit is assembled; and

a planar strap having an aperture therein adapted to allow passage of said upper portion of said chosen one of said variety of shaft-actuator assemblies and affixable over said switch housing for retaining said chosen one of said variety of shaft-actuator assemblies, said circuit board, and said wiper shoe within said switch housing when said kit is assembled.

23. The kit of claim 22, further comprising a control knob adapted to be received on said upper portion of said chosen one of said variety of shaft-actuator assemblies when said kit is assembled.

24. The kit of claim 22 wherein said anchor means further comprises:

a spline cylinder attached and perpendicular to said interior surface of said floor; and

a reset gear attached to said interior surface of said floor and surrounding said spline cylinder.

25. The kit of claim 22 wherein said anchor means further comprises:

a spline cylinder attached and perpendicular to said interior surface of said floor; and

a reset gear attached to said interior surface of said floor and surrounding said spline cylinder.