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.
Limit Switch: Building a Solid Foundation for Precise Control
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.
| Production Series | ME-8104 | Operating speed | 5mm-0.5m/s |
| Switch Shape | Rectangle | Actuator | Zinc Alloy, Stainless Steel, Brass |
| Color of shell | Blue | Housing Sleeve | Plastics, alloys |
| Mechanical Life | Ten million times | Button Pin | H62 Copper alloy |
| Electrical Life | The 500 thousand time | Rubber Ring | SIL silica gel |
| Protection Level | IP65 push button switch | Action type | self-reset |
| Rated Voltage | 110V（DC） 250（AC）switch | Contact resistance | <25 |
| Rated Current | 0.4A（DC）5A（AC）button switch | Insulation voltage | 415V |
| Rated operating frequency | 50/60Hz | Sealing material | Oil-resistant rubber |
| Operating Temperature | -35℃~+70℃ | Contact | Silver contacts |
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:
- The sensor cost, which varies depending on the type and precision required for different applications.
- Costs associated with intermediary structures and the requisite space for installation, such as the design of actuating elements, limit blocks, and mounting space.
- 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:
- 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.
- Implement “precision position contact sensors” that eliminate the need for intermediate structures, thus reducing costs, while delivering high precision, longevity, and dependability.
- 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
- What is the voltage range of a limit switch? Answer: Typically, limit switches operate within a 24-240V range, ensuring stability and safety.
- 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.
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