Is your company looking to shorten design cycles and bring products to market faster? Are you looking to reduce supply chains and the number of suppliers you deal with? Have you considered offloading portions of your product design, freeing up your designers to focus on the more critical aspects of creating new products?
It’s very common for the user interface to your product to include a self-contained sub-assembly or module that plugs into a larger assembly or the end product itself. Such a sub-assembly often consists of a printed-circuit board (PCB) or lead frame that includes an electromechanical switch or sensor, complementary electronics, possibly a source of illumination, and a means of connection, all mounting within a package that ties into the end product.
Developing such an assembly requires evaluating and quoting dozens of vendors and then narrowing them down to the final half dozen. Add in the prototyping, development, and testing phases, and design teams quickly slow down with something as simple as finding the switch interface.
These challenges no longer have to be the concern of the original equipment manufacturer (OEM). Switch manufacturers today have had to adapt and expand capabilities and resources that are of value and benefit to traditional OEM customers on a worldwide level, through global manufacturing, design, and sales support.
Cars and Phones and More
Switch manufacturers are in the unique position of having seen their products integrated into all types of electronics, in some cases for 40 to 50 years. They know what makes for a successful integration and have also seen the designs that have failed. The best switch companies regard themselves as experts at providing their customers with not just the components, but also the packaged solutions.
For example, many automobile manufacturers are simplifying their automatic shifters to reduce component count and vehicle weight while providing drivers a cleaner, more contemporary look. To do so, shift modules are becoming more electronic in makeup. Some companies originally developed an electromechanical switch for this application and then took it further by developing the module for simple integration into the same application for a number of automobiles.
Because the costliest component in this bill of materials was the switch, automotive manufacturers looked for a vendor who not only controlled the switching solution, but also provided added value in terms of designing the solution to best fit the application, i.e., the ability to integrate the same solution from platform to platform, easily integrating it into each vehicle.
Meanwhile, many consumer navigation devices in the U.K. now include an emergency “999” button, the equivalent of “911” in the U.S. The challenge switch manufacturers face is designing a solution that eliminates the possibility of accidental actuation while also integrating illumination for the other switches. One successful answer is a complete module groomed for a satellite-navigation software company.
The solution includes four uniformly lit tactile switches with the “999” switch recessed into the module to prevent accidental actuation (Fig. 1). It includes a device with a decorated façade including painted and laser-etched buttons and company logo plus a wire harness for interfacing with the receiver box, providing a complete module and solving a major challenge for the customer.
This isn’t just occurring in the automotive and consumer markets. From medical to marine and other industries, switch manufacturers are now working more closely with customers to increase functionality, improve efficiency, and develop complete solutions.
Functionality, Performance
To realize higher flexibility, look to the switch manufacturer for designs beyond the switch itself. As switch dimensions become more critical, it is imperative to work closely with customers to discern all the details they require. Now it is less about the switch being mountable to a PCB or adding wire leads or a connector and more about defining all design problems.
With switch manufacturers now dealing with the entire module, they are spending more time with customers determining potential impacts on the module in the particular application. For example, could the module be rubbing on a cable? Is there any vibration that may cause a problem in the application? Switch manufacturers must now consider these elements.
In the marine industry, customers need to replace mercury float switches for environmental reasons. The challenge was to replace the float switch with a sealed switch that is robust enough to withstand the harsh environment, conform to environmental standards, and ensure reliability (Fig. 2). Again, it’s not just about the switch, but also providing the connector and gasket in a sealed module as well as the assembly in the end application.
By working closely with customers in all phases of the design process, switchmakers can identify materials that interface with the operator. Those in the actual contact mechanism can be re-evaluated and altered to conform to performance, reliability, lifespan, and robustness standards. Sealing is typically required in harsh environments associated with automated assembly processes and other demanding applications, as noted above.
The medical market is perhaps the most demanding in terms of reliability. Due to its applications, there is little, if any, room for error. For example, one C&K Components customer needed a counting mechanism for electronic staples.
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