Monthly Archives: April 2024

At FILN, every switch action is not just a simple connection, but a pursuit of precise control and unparalleled performance. As a flagship company leading the industry standard, we are full of detailed focus and deep thinking for the manufacture of every limit switch. Let’s explore the world of FILN limit switch together and understand the profound principles behind their design, function, and application.

In the automation control system, the limit switch plays a vitally important role. As a link in the control chain, their reliability and accuracy directly affect the stable operation of the entire system. From the subtle touch of the Whisker limit switch to the stable rolling of the Roller limit switch, and the rigorous design of the Roller-lever limit switch, no part is negligible. At FILN, we understand the application scenarios and corresponding needs of each switch, whether it is a Normally Open Limit Switch or a Normally Closed Limit Switch, we can provide precise customization services.

The product to be introduced this time is the vertical MIN LIMIT switch of the ME series. It includes models such as ME-8104, ME-8107, ME-8108, etc. The overall design is miniaturized and suitable for small spaces. The shell is blue and its specific information is as follows:

Alloy body, plastic cover

The terminal part is fully open, easy for wiring

Working current range: 0.4A-5A

Product certification: UL, CSA, CE, CCC

Working voltage: 250VAC, 115V.DC

Protection level: IP65

Shell size: 56×21 mm

1.The Core Design of Limit Switches

1.1 Structure and Essential Materials

To explore our limit switches, we start with their structure and essential materials. A high-quality limit switch needs reliable materials to build, it is not just a simple tool to carry current and voltage, but the product of exquisite craftsmanship. From the corrosion-resistant metal shell to the accurate electrical contacts, the choice of every part is the result of careful design and multiple tests. The limit switch mainly includes switching elements, terminals, switch operators, and transmission parts.

1.2 Material Selection and Application

In order to meet application requirements under various working conditions, both Normally Open and Normally Closed Limit Switches use materials that can withstand severe environmental tests, whether it is extreme temperature or humidity, FILN switches always maintain their excellent performance. The shell of the limit switch usually uses metal or plastic materials, and oil-resistant rubber materials and polytetrafluoroethylene pipes are used as sealing materials.

1.3 Working Principle and Types of Limit Switch

The working principle of the limit switch is to operate the built-in micro switch through mechanical motion or physical force, thereby realizing circuit on-off control.

• According to the structural forms

Direct-action (button-style) limit switch: the same principle as the button switch, the speed of the button switch depends on the machine operating speed.

Roller limit switch: make contact with the measured object through the roller, the rotation of the roller drives the internal mechanism action.

Point-action limit switch: make contact with the measured object through the lever or swing arm, the internal mechanism acts by force.

Combined limit switch: integrates various structural forms to meet different application needs.

• According to the working principle

Mechanical: by using the movement or force of mechanical parts to achieve circuit switching.

Electronic sensing: detect or approach the target object by the principle of induction, capacitance, etc.

Photoelectric: detect the obstruction or reflection of the target object by using the photoelectric principle.

• Contact or not

Contact limit switch: the moving parts of the mechanical equipment contact with the switch, and the switch acts by mechanical contact to control the movement range of the device.

Non-contact limit switch: adopts the principle of magnetic induction. When the moving parts get close to the switch, magnetic induction makes the switch act, hence physical contact is produced.

2.The Subtle Art of Manufacturing Process

To produce a stable and efficient limit switch, in addition to relying on high-quality materials, the manufacturing process also plays a decisive role.

2.1 Control of Process Flow

At FILN, the production of each limit switch is the crystallization of refined craftsmanship and modern technology. We strictly control every step from raw material processing to final assembly, ensuring that every step meets the highest quality standards.

The manufacturing technology of the limit switch mainly ensures its accuracy and stability from the following aspects:

Shell material and protection

The shell of the limit switch usually uses metal or plastic material to provide mechanical strength and environmental stability. A sealant material like oil-resistant rubber material and teflon pipe is used to prevent dust, oil, etc. from entering and causing damage to the contacts.

Also, a drip-proof, water-tight design is needed, and appropriate connectors and cables are selected to improve the protection level.

Internal structure and drive mechanism

The micros witch built into the limit switch has different driving mechanisms such as piston type, corridor chain lever type, and rotating lever, corresponding to different application scenarios. The design of the driving mechanism directly affects the operating characteristics and sealing performance of the limit switch, and needs to be optimized according to the specific application.

Connection point protection and reliability

To prolong the life of the contacts and prevent noise, it’s necessary to use a surge absorber and other contact protection circuits. But if not used properly it may have the opposite effect.

The limit switch also needs to consider the impact of chemical corrosion, vibration shock and other factors on reliability, and adopt corresponding protective measures.

In summary, the manufacturing technology of a limit switch involves the shell material, protective design, internal structure, driving mechanism, as well as contact protection, etc and needs to consider all the factors for the performance, reliability and cost of the product for optimization design.

2.2 Protection Level and Manufacturing Standards

FILN switches not only meet the basic functionality but also have a high level of protection, can adapt to various environmental conditions, such as dust, water, etc., ensuring long-term stable performance.

In terms of manufacturing standards, this product meets the safety level requirements of EN ISO 13849-1 and the requirements of IEC 60947-5-1 in terms of insulation, pollution levels, etc. .

3. In-depth Analysis of Precision Performance Parameters

The performance indicators that an excellent limit switch possesses is the basis for widespread application.

3.1 Compatibility of Current and Voltage

Limit switches play a vitally important role in industrial design, and a huge driving force behind it is the management of current and voltage. According to the book “Electrical Engineering Handbook”, the working current of the limit switch is generally between 0.1-10A, and the voltage is generally between 24-240V. Current and voltage in this range can ensure the stable operation of the switch and avoid the device damage and safety risks brought about by excessive current and voltage. Our limit switch design is used to meet different current and voltage needs, whether it is a Normally Open Limit Switch or a Normally Closed Limit Switch, can provide precise control.

3.2 Adherence to Mechanical and Electrical Life

Mechanical life and electrical life are two key indicators for measuring the quality of a limit switch. Through continuous innovation, we ensure the long-term durability of the product. For any company, cost optimization is a problem that must be considered in its operation. On this point, the limit switch plays a huge role. According to the book “Industrial Automation Technology”, the use of limit switch control can make the equipment run more accurately, reduce the defective rate in the manufacturing process, thereby saving a lot of raw material costs. At the same time, the fewer maintenance needs and long service life of the limit switch also greatly reduce the maintenance costs in the later period. For example, a metal limit switch from Omron has a life of more than 5 million times. Such a long life allows companies to greatly reduce the frequency of equipment updates and save a lot of funds.

4. Performance of Limit Switch in Practical Applications

The real advantage lies in the stable performance in actual applications, and FILN switches have been verified in many fields.

4.1 Diversity of Application Scenarios

From mechanical automation to logistics transportation, all the way to safety monitoring, FILN limit switches can all play their roles. Not only is stability guaranteed, but precision and reliability are also its significant features.

The application fields of limit switches mainly involve the following aspects:

Limit switches are mainly tested in situations which require special demands for mechanical strength and environmental perception, such as situations that demand protection for the built-in micro-switch shell damage from external forces, water, oil, gas, and dust, etc.

Limit switches are widely evaluated in industrial automation, mechanical equipment, elevators, access control systems and other fields, and need to meet the performance and reliability requirements of these scenarios.

The driving mechanism and operating characteristics of the limit switch also need to be selected according to specific application scenarios, such as the piston type, lift table chain lever type or rotary lever type.

In conclusion, the materials and application fields of limit switches all need to be chosen and designed according to the specific usage environment and performance requirements, to ensure they can work reliably. The limit switch, as a key component for detecting a position and limiting travel, plays an important role in various industrial automation equipment, ensuring device safe operation.

5.Product Certification: A Quality and Safety Endorsement

Every switch that passes through the production line is certified, ensuring safety and reliability.

5.1 The Importance of International Certification

By passing CE, UL, and other international certifications, FILN limit switches not only gain trust in the domestic market but also have widespread influence on the international market. The importance of gaining certification also reflects in these aspects:

To ensure product quality and performance

By passing certification tests from authoritative agencies, limit switches can ensure that in terms of structure, materials, electrical performance, and environmental protection, they meet the requirements of related international standards, ensuring their quality and reliability.

To meet different national and regional legal requirements

Different nations and regions have their own certification requirements for industrial products, gaining corresponding certification helps with limit switches entering these markets and selling smoothly.

To increase the product’s international competitiveness

By gaining safety certification marks like UL, CE, CCC, etc., which are internationally recognized, the trust level and influence of limit switch products in the global market can be enhanced, improving their international competitiveness.

To meet special application environment needs

For some special application environments, like explosion-proof, high-temperature resistance, corrosion resistance, etc., by passing related certifications, limit switches can ensure they meet these strict usage condition requirements.

5.2 Certification Standards and Market Orientation

Certifications serve not only to attest to FILN’ s product quality but also to demonstrate our dual commitment to safety and performance. With these certifications, our limit switches ensure quality and performance and smoothly access global markets, aligning with market trends and boosting international competitiveness.

6.Strategic Significance of Cost Control in Product Development

FILN is acutely aware of the important balance between cost control and maintaining product quality and performance.

6.1 Cost Composition and Control

Striving for excellence in materials and technology, FILN meticulously manages costs by optimizing manufacturing workflows and enhancing efficiency. The cost components of limit switches primarily encompass:

1. The sensor cost, which varies depending on the type and precision required for different applications.
2. Costs associated with intermediary structures and the requisite space for installation, such as the design of actuating elements, limit blocks, and mounting space.
3. Costs pertaining to assembly and ongoing maintenance, which rise with labor involved in installation and adjustments, and with future repair and replacement of the vulnerable limit switches due to wear and tear.

6.2 The Art of Balancing Performance and Cost

FILN’s limit switches not only deliver superlative performance but also come at a competitive price, offering customers exceptional value. To minimize costs while achieving desired performance, consider the following strategies:

1. For regular use, such as in household appliances, opt for sensors that balance lower precision and reliability with cost savings. Conversely, industrial applications demand higher-grade sensors at a greater cost, reflecting the need for enhanced reliability.
2. Implement “precision position contact sensors” that eliminate the need for intermediate structures, thus reducing costs, while delivering high precision, longevity, and dependability.
3. Thoroughly assess the scope and likelihood of malfunctions to tailor reliability, reducing expenses for scenarios with limited impact or low risk, while investing in robust solutions for critical applications with extensive consequences and higher risk.

To summarize, the primary costs for limit switches include the sensors, intermediary structures, installation space, and maintenance. Well-informed decisions about sensor choice and technological approaches, matched to the application, pare down overall costs without compromising on requirements.

7.Frequently Asked Questions

1. What is the voltage range of a limit switch? Answer: Typically, limit switches operate within a 24-240V range, ensuring stability and safety.
2. Do limit switches offer cost savings? Answer: Absolutely. Limit switches enhance operational precision, reducing material waste and thereby saving costs. Their durability also diminishes maintenance expenses over time.

Conclusion:

FILN reiterates its steadfast commitment to quality, pursuit of excellence in design, and our focus on professional customer service. As a dependable partner for both stock and custom solutions, FILN’ s aim is to propel continual innovation, refining our high-caliber limit switch and other push button switch offerings.

We appreciate your choice of FILN — where, much like our limit switches, our service and dedication are unwaveringly reliable and precise.

            How to connect more types of pushbutton switches?          

1.FILN Button Switch Example:

1.1 Product Introduction:

Welcome to our latest product introduction, the 22mm Gravity push button switches, a metal push button switch  designed specifically for nail guns shooting. This button, a robust metal push button switch, is crafted from high-quality stainless steel 304, featuring two connection legs/wires, capable of handling up to 250V and 5A of current. Its compact design, measuring only 22mm in diameter without a light, makes it suitable for various nail guns shooting environments. Our clients from the USA have requested custom push button switches for nail guns, with high demands for product quality and stability. We are committed to providing them with the highest quality push button switches and services.

1.2 Customization Needs:

Through communication with our client, we discovered that the push button switches provided by their previous supplier could not withstand the impact force of nail guns shots, leading to damage and disintegration of the nail guns head after a few uses. This significantly impacted the quality and user experience of the nail guns. Consequently, the client reached out to several Chinese button companies, including FILN, hoping for a better metal push button switch solution.

1.3 Innovative Response Measures:

Based on the situation, we recommended a more stable 22MM stainless steel metal push button switch structure and provided clear product effect pictures. Considering the traditional push button switches’ susceptibility to wear and tear in nail guns shooting environments, we introduced innovative measures, adding a spring structure to counteract the impact force. Furthermore, we customized the head and internal structure of the metal push button switch to withstand the impact force of nail guns gravity shooting, thereby enhancing the product’s durability and reliability. Compared to push button switches provided by previous suppliers, our product offers better resistance to nail guns shooting, avoiding damage due to impact.

2.Understanding the Functions of the 22MM Gravity Push Button Switches

2.1 Main Functions:

The 22MM Gravity Metal Push Button Switch is a self-locking switch, also known as a keep switch. Its design allows the switch to remain closed after being pressed until pressed again. This type of push button switches is ideal for applications that require maintaining the open or closed state until the user decides to change it, controlling the circuit current with a simple press, such as for lighting control or powering electronic devices.

2.2 Types of 22MM Gravity Push Button Switches:

The 22MM Gravity Metal Push Button Switch offers Different pressing functions: a locking push button switches, which locks the switch in the open position when pressed and releases it upon another press; a momentary button switch, activating the switch when pressed and deactivating it when released. There are also waterproof, illuminated, and non-illuminated versions of the 22MM Gravity Metal Push Button Switch, allowing users to choose the most suitable switch based on their specific needs and application scenarios. The diversity and reliability of these push button switches make them indispensable components in electronic and electrical systems.

3.Application Scenarios for the 22MM Gravity Metal Push Button Switch:

The 22MM Gravity Metal Push Button Switch, due to its compact size, reliable performance, and versatile design, is widely used across various scenarios. These push button switches not only fulfill basic switching functions but also adapt to special environments and needs, becoming an essential part of many fields. Here are some typical application scenarios:

3.1 Nail Guns Applications:

Trigger Control:In nail guns design, the 22MM Gravity push button switches can serve as part of the trigger mechanism. Typically set as a momentary trigger type, pressing the button activates the nail guns firing mechanism. This setup demands the push button switches to have quick response characteristics and enough durability to withstand frequent use.

Safety Lock:The 22MM Gravity push button switches on nail guns can also act as a safety lock. In this scenario, the switch controls the nail guns’ s safety mechanism, preventing accidental firing. Users must first disable the safety lock (by pressing or unlocking the button switch) before the nail guns can be activated and ready to shoot. This requires the push button switches to not only be reliable but also to provide clear feedback, ensuring users can clearly understand the safety lock’s status.

3.2 Industrial Control Systems:

In industrial production and control systems, the 22MM Gravity push button switches is used to start and stop machines, control production line operations, and activate safety systems. Their durability and reliability make them ideal for industrial environments, especially where dust proof, waterproof, or high-temperature resistance is needed.

3.3 Household Appliances:

From microwaves to washing machines, from coffee machines to air conditioners, the 22MM Gravity push button switches is found in various household appliances. They offer a simple and intuitive way for users to control the appliance’s switches and select functions.

3.4 Entertainment Devices:

In gaming consoles, electronic musical instruments, professional audio equipment, and other entertainment products, the 22MM Gravity push button switches plays a crucial role. These switches are required to provide a good tactile response and speed, and sometimes, they need unique designs and customized functions.

3.5 Outdoor Equipment:

For outdoor sports equipment, camping lights, boat control panels, and other applications, the 22MM Gravity Metal Push Button Switch is widely used for its waterproof and dust proof qualities. These scenarios demand switches that can withstand challenges from natural environments, such as rain, mud, and dust.

Through these application scenarios, we can see the versatility and flexibility of the 22MM Gravity Metal Push Button Switch, making it an indispensable component in various industries. Whether in high-demand applications in extreme environments or for convenient operations in daily life, the 22MM Gravity Metal Push Button Switch provides reliable and efficient solutions.

4.Understanding the Custom Features of the 22MM Gravity Metal Push Button Switch

• 4.1 Durability and Reliability:

The addition of a spring structure and customized internal structure allows the switch to withstand the impact force of nail guns shooting, enhancing the product’s durability and reliability.

• 4.2 Lock Design:

The lock design ensures the push button switches remains stable during use, preventing accidental activation.

• 4.3 IP67 Waterproof Rating:

Meeting the IP67 waterproof standard, it operates stably in humid environments, ensuring the product’s reliability and safety.

• 4.4 Wide Applicability:

Due to its compact size and high durability, it’s suitable for various nail guns shooting environments, providing users with a stable experience.

5.Factors to Consider When Choosing a 22MM Gravity Metal Push Button Switch

When selecting a 22MM Gravity Metal Push Button Switch, several factors need to be considered to ensure the choice meets application requirements and environmental conditions. Here are some key factors:

1. Electrical Specifications:

Consider the switch’s voltage and current carrying capacity to ensure they meet your circuit requirements. The 22MM Gravity Metal Push Button Switch typically indicates the maximum voltage and current it can handle, such as 250V and 5A.

2.Material:

The material of the metal push button switch is crucial for its durability and suitability for the environment. Stainless steel 304 is a common material because it offers good corrosion resistance and structural strength, suitable for various environments.

3.Protection Level:

Choose the appropriate protection level based on the special requirements of the usage environment (e.g., exposure to water, dust, etc.), such as the IP67 waterproof rating to ensure the switch operates normally in humid conditions.

4.Mechanical Life:

Check the switch’s mechanical life, i.e., the number of operations the switch can perform. This is particularly important for applications expected to be used frequently.

5.Installation Method:

Consider the switch’s installation method and size to ensure it can fit your panel or device. 22MM refers to the mounting hole diameter, one of the dimensions to consider when choosing.

6.Operation Type:

Choose the operation type suitable for the application, such as momentary (closes when pressed, opens when released) or self-locking (remains closed after being pressed, requires another press to open).

7. Functional Features:

Select push button switches with additional features as needed, such as LED indicators, locking function, or different color options for the button.

8.Certification:

Check if the switch has relevant safety and quality certifications, such as CE, UL, etc. These certifications indicate that the switch complies with international safety standards.

9.Brand and Supplier:

Choosing a reliable brand and supplier can ensure product quality and after-sales service. Research the supplier’s reputation, looking at user reviews and feedback.

10.Cost-Effectiveness:

While price should not be the sole consideration, ensure the selected product is cost-effective while meeting all other requirements.

By considering these factors comprehensively, you can select the 22MM Gravity Metal Push Button Switch that best suits your specific application needs and environmental conditions.

6.Connecting Process for the 22MM Gravity Metal Push Button Switch

The process of connecting the 22MM Gravity Metal Push Button Switch requires attention to accuracy and safety to ensure the switch works correctly and safely within the circuit. Here is a basic guide for connecting the 22MM Gravity Metal Push Button Switch:

6.1 Preparation of Tools and Materials:

• 22MM Gravity Metal Push Button Switch
• Appropriate gauge wire
• Wire stripper
• Screwdriver
• Soldering tools (if soldering is required)
• Insulating tape or heat shrink tubing

6.2 Wire Preparation:

Stripping: Use a wire stripper to remove about 1cm

of insulation from the wire’s end, exposing the copper wire.

Cleaning: If the wire end needs soldering, clean the

copper wire to remove oxidation.

6.3 Connecting the Wire to the push button switches:

Identify Terminal Points: Check the 22MM Gravity Metal Push Button Switch for its terminal points, likely marked as Normally Open (NO), Normally Closed (NC), and Common (COM).

Normally Open (NO): Contacts that close only when the switch is pressed.

Normally Closed (NC): Contacts that are closed when the switch is not pressed.

Common (COM): A terminal connected to either NO or NC contacts, completing the circuit.

Connecting the Wire:

1.For screw-fixed type terminals, insert the stripped wire end into the corresponding terminal hole and tighten the screw with a screwdriver to ensure a good electrical connection between the wire and the terminal.

2.For solder-type terminals, use soldering tools to solder the wire to the corresponding terminal. Be mindful of accuracy and safety during soldering to prevent overheating damage to the switch.

6.4 Testing and Inspection:

After connecting, use a multimeter’s continuity test function to check if the switch’s open and close states meet expectations, ensuring no short circuits or open circuits. Inspect all connection points for firmness and reliability, ensuring no looseness.

6.5 Final Installation:

Install the 22MM Gravity Metal Push Button Switch in the designated position, ensuring it is securely fixed. Use insulating tape or heat shrink tubing to insulate all exposed wires and solder joints, preventing electric shock or short circuits.

6.6 Safety Precautions:

Before performing any electrical work, ensure the power supply is disconnected to avoid the risk of electric shock. If unsure about safely completing the installation, consult a professional. Ensure the wires and switches used meet the voltage and current requirements of the intended circuit. By following these steps and precautions, you can safely and effectively connect the 22MM Gravity Metal Push Button Switch, ensuring its correct function and long-term reliability within the circuit.

7.Maintenance Methods for the 22MM Gravity Metal Push Button Switch

Proper maintenance techniques can extend the product’s lifespan and maintain its reliable quality.

7.1 Regular Inspection:

Visual Inspection: Regularly visually inspect the switch for any obvious damage, corrosion, or wear, especially around the button portion and terminal connections, which are most prone to issues.

Mechanical Operation Check: Manually operate the switch to ensure its action is smooth and without abnormal noises. Any difficulties or unusual conditions might indicate wear or internal damage.

7.2 Avoid Mechanical Damage:

Avoid Excessive Force: During use, avoid applying excessive force to the switch, which could cause mechanical damage or damage to the internal structure.

Protect the Switch from Impact: Where possible, avoid impact to the switch from hard objects, especially during handling or installation.

7.3 Cleaning and Maintenance:

Regular Cleaning: Use a dry soft cloth or slightly damp cloth (ensuring no water ingress) to clean the switch surface. For the switch’s terminal connections, compressed air can be used to blow away dust and debris.

Keep Dry: Try to keep the switch environment dry to prevent corrosion or short circuits due to moisture. For waterproof switches, ensure good sealing performance and regularly check the integrity of the waterproof sealing ring.

7.4 Replacement and Upgrading:

Replace Damaged Push Button Switches: If a switch becomes irreparably damaged or its performance significantly declines, replace it promptly to avoid affecting the entire system’s reliability.

Upgrade Aged Push Button Switches: For switches that have been in use for a long time, consider upgrading them according to the latest technical standards to enhance the system’s overall performance.

About FILN

FILN not only produces metal push button switch but also customizes a variety of plastic push button switches, waterproof push button switches, metal indicator lights, plastic indicator lights, waterproof rocker switches, high-current rocker switches, etc., based on customer requirements. The company, with its diversified and customized product lines, offers clients a broad range of choices, showcasing strong production capability and flexibility. FILN is committed to providing customers with high-quality, innovative metal push button switch products, meeting market demands, and creating more possibilities for customers.

Conclusion:

The 22mm Gravity Metal Push Button Switch is a high-quality product we have customized for the nail guns shooting environment, featuring excellent durability, reliability, and stability. Through the FILN company’s 22mm Gravity Metal Push Button Switch example, we can see how customized products provide precise solutions for specific application scenarios, meeting unique customer needs. From needs analysis to design, testing, and production, every step reflects a commitment to innovation and quality. As technology advances and market demands evolve, customized products will continue to play a crucial role in offering personalized solutions and driving technological innovation. We will continue to innovate, providing better products and services for our users. If you are interested in our products or have any customization needs, please feel free to contact us.