Everything you should know about Micro Switch

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What Is a Micro Switch?

The micro-switch is a switch that operates rapidly with a very small amount of force. The micro-switch is also called a miniature snap-action switch. It is extremely reliable, fast, and efficient to operate, and is also known as a miniature snap-action switch. It is impossible to create smart appliances without micro switches. They are used in many modern-day smart applications. Microswitches are often used as safety devices because of their reliability and sensitivity. They are used to prevent the closing of doors when something or someone is in the way and other similar applications.

The micro switch has three pins: Common (C), Normally Closing (NC), and Normally Opening (NO). Here, the Common pin is an input pin, the NC pin is Output 1, and the NO pin is Output 2.

With its tiny contact gap, The micro switch is a snap-action precision switch for logic-level and power-duty loads. The switch has options like SPDT, SPNO, or SPNC, and offers power-duty switching through silver alloy contacts. Different electrical terminations are available, and logic-level control can be achieved by silver alloy or gold-plated contacts.

 

How Does a Micro Switch Work?

A micro switch is equipped with an actuator that lifts a lever when pressed to move the contacts into the proper position when depressed. When pressed, micro switches often make a &#;clicking&#; sound. Often, micro switches have mounting holes so they can be quickly mounted and secured into place. Due to their long life, they rarely need to be replaced and require little maintenance since they are such a simple switch.

The working principle of a micro switch is that when it touches an object, the contacts change position. Thus, the principle of operation of this switch is mainly as follows.

The normally closed pin of the circuit is opened and the normally open pin is closed when you press the lever of the switch. In the same way, when you open the lever of the switch, then the normally closed or NC pin of the circuit will carry the current, while the normally open or NO pin of the circuit can isolate electrically.

The tipping point mechanism is also the basic feature of the micro switch. So, this feature will help to generate certain tripping points and reset points wherever the contacts will change the state.

 

Micro Switch Circuit

Following is the circuit diagram for the micro switch. The circuit shown below uses a micro switch to control two LEDs with a battery. The micro switch has three terminals, which are C, NO, and NC. This circuit can be connected in the same way as the circuit shown below.

There is no connection between the NO terminal and the common terminal of the switch when the lever is pressed. Therefore, the Green color will turn on once the lever is pressed.

After the lever has been raised, the common terminal and the NC terminal of the switch will be connected, so the NC terminal of the switch will not be connected, consequently the Blue color LED will turn on. Based on the application, we can use the switch in NO or NC mode.

 

How is a Micro Switch constructed?

In order to construct a micro switch, many different components are required, including a plunger or actuator, cover, moving piece, support, NC terminal, NO terminal, contact, and, moving arm.

 

 

Plunger

Also known as an actuator, the plunger is a type of mechanical component used to manually control a circuit by turning it on/off.

 

Cover

The cover of the switch is for protection against external forces.

 

Moving Piece

The moving part that applies the operating force to the contacts is called the actuator.

 

Support

This is used to help hold the micro switch in place.

 

NO Terminal

NO terminals, which are also referred to as normally open terminals, indicate that the switch's contacts will be open by default, thus no current will flow through the circuit if you connect them.

 

NC Terminal

Known as a Normally Closed terminal, the NC terminal, as the name implies, performs the opposite function of the NO terminal. The contacts are closed, allowing current to flow through the circuit.

 

Contact

The switch contact is a piece of conductive material, usually metal. Establishing or breaking electrical continuity is the primary function of this component.

 

Moving Arm

The moveable arm is a lever in a switch that is used for activation and operation of the micro switch.

 

 

Different Types of Micro Switches

In micro switches, we can choose the type of lever terminals based on the application. Pin Plungers, Hinge Roller Lever, Rotating Operation, Short Straight Levers, Standard Straight Levers, Long Straight Levers, Extended Straight Levers, Small Simulated Roller Levers, Standard Simulated Roller Levers, Roller Levers, and L-Shaped Levers are some of the lever terminals available. We&#;ll discuss some types of micro switches in the below.

 

Rotating Operation Micro Switch

The rotation operation micro switches are commonly used with low torque actuators. Therefore, this type of switch can be used to detect light objects such as paper currency.

 

Pin Plunger Micro Switch

Pin plunger micro switches are suitable for direct, short strokes, hence allowing for the detection of high-precision positions directly. Additionally, since their overtravel is the shortest, they also require consistent stoppers.

Spring Pin Plunger Micro Switch

A spring plunger micro switch has a longer overtravel than a pin plunger. However, you can use this switch for similar applications. When using this switch, make sure the load is centered on the plunger due to the slightly larger plunger diameter.

 

Hinge Roller Lever Micro Switch

A hinge roller lever micro switch usually has a roller connected to the lever. This makes the switch suitable for high-speed camera operation.

 

Leaf Spring Micro Switch

The leaf spring micro switch has a greater stroke because it is powered by a strong leaf spring. Therefore, you can use it for cams or cylinder drives at a low speed. To prevent damage and because the leaf spring has a permanent bearing point, it is essential to keep the overtravel switch in a specified application.

 

 

 

Panel Mount Plunger Micro Switch

This micro switch has the largest overtravel compared to other types of switches. This switch can be mounted on a panel by using a nut and a hex nut. After that, you can operate this switch either by hand or by mechanical means. Furthermore, this switch can be used with a slow-speed cam.

 

 

The differences between Micro Switch and Limit Switch

 

Micro Switch

Limit Switch

Small & Sensitive

electromechanical device

AKA: miniature snap-action switch.

AKA: the end switch or position switch.

Acts as a switch to turn an electrical circuit on or off, or to close a circuit automatically in response to a mechanical load.

 Functions to sense the object&#;s presence or absence.

A micro switch consists of two limit switches, such as NO and NC, that operate in conjunction with each other & share a common terminal.

The limit switch can be actuated by object presence or machine part motion.

The types of micro switches include: plunger, spring plunger, short spring, panel mount, leaf spring, leaf lever, roller leaf spring, and so on.

The types of limit switches are whisker, roller, lever limit, and plunger.

It has less contact gap.

It has a high contact gap when compared with a micro switch.

 

 

How To Maintain a Micro Switch

Maintaining a micro switch is essential to ensure its longevity and reliable operation. Here are some steps you can follow to properly maintain a micro switch:

1. Keep it clean: micro switches are sensitive to dust and debris, so they must be kept clean. It is recommended that you use a dry cloth to wipe the surface of the switch periodically. Avoid using chemical cleaning fluids such as water solutions as they may damage the switch.

2. Avoid harsh environments: micro switches should not be used in environments with explosive or flammable gases. These environments can cause damage to the micro switch and compromise its safety.

3. Inspect Contact Parts: The touch parts of the micro switch must be inspected frequently to ensure proper operation. Check that the touch of the switch is okay, that the limit distance is within the range, and that the force and speed of touch are normal.

4. Monitor voltage and current: The current and voltage can have a significant effect on the switch, so it's important to check the circuit's voltage and current at regular intervals. Make sure the voltage stability is maintained to avoid damage to the switch.

5. Periodic maintenance: In automation equipment, micro switches must be periodically checked every 2 to 3 months to observe any damage to the external power supply. This maintenance can help avoid other consequences that may result from a damaged switch.

By following these steps, you can maintain a micro switch and ensure its reliable operation. Remember that regular maintenance is essential to keep the switch functioning properly and to avoid potential damage or safety hazards.

 

Advantages & Disadvantages of micro switches

Advantages:

Micro switches usually have accurate performance. They are of reliable switching and inexpensive, requiring less maintenance nad can last a long life. Those switches are versatile, often resistant to water and dust, and its arcing damage can be reduced by arcing fast switching speeds.

 

Disadvantages:

There are some problems like low-quality parts or bad components in most of these switches. Component burns, depreciation, and sudden failure are some of the failures that can affect a Micro switch.

 

 

Micro Swicth Applications

Micro switches are versatile electronic components used in a wide variety of devices. They are often used to create timing mechanisms when combined with other devices. Micro switches are an integral part of our daily lives and can be found in home appliances, automobiles, industrial equipment, and more.

They can also be used as control switches and limit switches, used in printers to detect paper jams, and in control circuits of various devices such as small motors, lamps, and solenoids.

In addition, micro switches are used in vending machines, where they act as jam detectors and can detect coins as they are inserted into the machine. They are also important electronic components for detecting the open/closed position of valves, as safety devices in elevators, and as door interlocks in microwaves.

Micro switches play a critical role in the proper functioning of many devices, from household appliances to industrial equipment. Their versatility and reliability make them an essential component in many electronic applications.

 

Final Words

If you're working on a project that requires the use of micro switches, you may be considering sourcing them. Elecrow is a leading supplier of electronic components and offers component-sourcing services for various applications. 

In addition to micro switches, Elecrow offers other electronic component sourcing services such as sensors, LEDs, and more. Elecrow has a user-friendly website that makes it easy to find the components you need, and they offer fast shipping to customers around the world.

Overall, if you're looking for high-quality microswitches or other electronic components, Elecrow is worth considering. With their wide selection of products and excellent customer service, Elecrow can help you find the right components for your project and ensure that you get them quickly and at a competitive price.

Also, if you are a DIY electronics enthusiast who is keenly focused on creating projects and wants to turn your ideas into reality, Elecrow offers Partner Seller Program to help you realize your ideas, Via Partner Seller Program you can produce your own electronic products, and sell them online for commercial purposes.

 Join Elecrow's Partner Seller Program to earn your benefits!

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A micro switch, a miniature snap-action switch, is a fast-acting switch used in automotive, industrial, and appliance applications for making and breaking an electrical connection. It uses a small actuator lever to produce a rapid switch with very little physical force.

Stick around, and I&#;ll take you through the nitty-gritty of how these micro switches work, their diverse types, and tips on selecting the right one for your needs. Plus, we&#;ll cover some practical wiring techniques and troubleshooting tips.

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What is a Micro Switch?

A micro switch is a small, susceptible switch requiring minimum compression. Micro switches are designed to be durable, typically operating reliably over millions of cycles. Micro switch&#;s high precision and reliability make them extensively valuable for various applications.

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How Micro Switch Work?

A micro switch works on the principle of mechanical action and electrical conductivity. It basically consists of one movable actuator- usually called an actuating lever- and one fixed contact point.

Mechanical action: When an outside force is applied to the actuator of the micro switch, it moves or flexes. This mechanic movement is usually very small but is enough to trigger the micro switch.

Electrical Conductivity: Due to the movement produced in the actuator, the movable contact point on the actuator comes either in contact or moves away from the fixed contact point within the micro switch. When the contacts touch, it completes an electrical circuit, allowing current to flow through the micro switch; this micro switch position is called the &#;closed&#; position.

Contact us to discuss your requirements of electric micro switch. Our experienced sales team can help you identify the options that best suit your needs.

Switching Status: Once the applied force by an external source is removed, or the threshold value is lowered below a certain limit, due to its spring or mechanical design, the actuator moves back to its previous position. This will move the contacts apart and break the electrical circuit, thus stopping the current flow. It occupies what is called the &#;open&#; position.

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What is a Micro Switch Circuit

This is the scheme of a micro switch. The following circuit uses a micro switch to control two LEDs with a battery. A micro switch has three terminals: C, NO, and NC. The same connection can be made to this circuit as in the circuitry below.

The micro switch&#;s NO and common terminals are not connected when the lever is pressed. Hence, the Green color turns on once the lever is pressed.

Once the lever is raised, the common terminal and the NC terminal of the micro switch will be connected; hence, the NC terminal of the micro switch will not be connected, so the blue LED will turn it on. We can use the micro switch in NO or NC mode per the application.

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Construction of Micro Switch

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A micro switch has several components that provide reliable, snap-action switching. Below is an explanation of the primary parts and their roles within the micro switch:

Plunger: The plunger is the part of the micro switch that the user interacts with directly or through an actuator arm or lever. When pressed, the plunger initiates the switch action.

Cover: The cover protects the internal components of the micro switch from dust, moisture, and external mechanical forces.

Moving Piece: This component is critical as it translates the mechanical force from the plunger into electrical action within the micro switch.

Support: The support holds all internal components in place, ensuring precise alignment and smooth operation.

Terminals:

• The NO terminal connects when the micro switch is activated (the plunger is pressed), allowing electricity to flow through the circuit.

• The NC terminal breaks a connection when the micro switch is activated, stopping the flow of electricity.

Contact: Contacts are the conductive part of the switch that either make or break the electrical circuit.

Moving Arm: The moving arm connects the moving piece to the contacts and transmits the actuation force to open or close the circuit.

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Types of Micro Switch

Subminiature Micro Switch

The subminiature micro switches design provides a considerable space-saving device compared with the other types and devices due to their smaller size for limited-spaced applications.

Subminiature micro switches are also frequently used in small electronic devices, computer peripherals, and light-clean equipment. Their dimensions are small enough to restrict the space within a device where you intend to fit this subminiature micro switch.

Standard Micro Switch

The main application areas of standard microswitches are household appliances, industrial equipment, and automotive systems. They represent an excellent medium-sized balance between compact size and robustness with many applicative cases.

Heavy-duty Micro Switch

Heavy-duty microswitches are used at places where higher durability is required, and we are looking ahead to keeping our loads high. Since these micro switches are more significant compared to the standard microswitch due to contact life and robustness, they can also be remarkably different in size depending on use.

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Applications for Micro Switch

Automotive: Used in door locks, turn signals, and more.

Industrial: Employed in control systems and safety mechanisms.

Consumer Electronics: Found in refrigerators, air conditioners, and cameras.

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How to Select Micro Switch?

1. Electrical Ratings

Consider the maximum voltage and current that the micro switch can handle. Ensure it matches or exceeds the requirements of your application to avoid premature failure.

2. Voltage and Current Capacity

Select a micro switch based on the voltage and current it will routinely handle. This helps prevent damage from overloads and ensures reliable operation.

3. Actuator Types

Lever Actuators: Ideal for applications where a simple lever can activate the micro switch.

Roller Actuators: Best for moving objects that may slide over the switch, providing a smooth operation.

4. Environment

Temperature Range: Choose a micro switch that can operate within the environmental temperature extremes of its intended application.

Ingress Protection (I.P.) Rating: Ensure the micro switch has an appropriate I.P. rating if exposure to moisture or dust is expected.

5. Pole and Throw Count

Determine the number of circuits the micro switch must control (pole) and how many positions each pole must connect to (throw).

6. N.O. Or N.C. Contacts

Normally Open (N.O.): Contacts that close when the micro switch is activated.

Normally Closed (N.C.): Contacts open when the micro switch is activated.

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EN-1 Standards of Micro Switch

Proof Tracking Index (PTI)

Tracking resistance index, i.e., maximum withstanding dielectric strength without short-circuiting between two electrodes attached to the switch sample while dropping 50 drops of 0.1% ammonium chloride solution drop by drop between the electrodes. Five levels are given. According to the UL Plastics Recognized Directory, the following table shows the relationship between these PTI and CTI values.

PTICTI Classified by UL Yellow Book500PLC level 1: 400 &#; CTI < 600
(Check with material manufacturer to see if the material meets CTI 500)375PLC level 2: 250 &#; CTI < 400
(Check with material manufacturer to see if the material meets CTI 375)300PLC level 2: 250 &#; CTI < 400
(Check with material manufacturer to see if the material meets CTI 300)250PLC level 2: 250 &#; CTI < PLC level 3: 175 &#; CTI < 250PTI and CTI values &#; Contact Us

Electric Shock Protective Class

Indicates the electric shock preventive level. The following classes are provided.

• Class 0: Electric shocks are prevented by basic insulation only.

• Class I: Electric shocks are prevented by basic insulation and grounding.

• Class II: Electric shocks are prevented by double insulation or enforced insulation with no grounding required.

• Class III: No countermeasures against electric shocks are required because the electric circuits operate in a low-enough voltage range (50 VAC max. or 70 VDC max.)

Number of Operations

Denotes the number of the durability test the norm gives. They are divided into the following classes, and the switch should carry the appropriate marking. A switch with a high switching frequency should endure 50,000 switching operations, while a switch with a low switching frequency should endure 10,000 operations to meet IEC norms.

Number of operationsSymbol100,,,,,,,000No symbol required6,,,,,,Durability Test IEC Standards &#; Contact Us

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Differences Between Micro Switch and Limit Switch

Size and Sensitivity

Micro Switch: Known for being small and sensitive, designed for minimal actuation force and quick response, ideal for precise control with little pressure.

Limit Switch: More robust, designed to detect object presence or absence, typically used in harsh environments requiring physical contact.

Function and Operation

Micro Switch: Turns electrical circuits on/off in response to mechanical loads, using a snap-action mechanism for quick, reliable operation.

Limit Switch: Acts as a sensor to limit mechanical part movement or detect objects, focusing on direct mechanical action over switching power.

Construction and Types

Micro Switch: Contains two limit switches (NO and NC) that operate together. Variants include plunger, short spring, panel mount, leaf spring, and more.

Limit Switch: Built to endure substantial forces, with types like whisker, roller, lever limit, and plunger designed for specific actions.

Contact Gap

Micro Switch: Smaller contact gap for quick operation.

Limit Switch: Larger contact gap, suited for applications requiring significant movement to activate the switch.

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Troubleshooting Common Issues

Electrical Failures

• Contact Failure
  • Caused by dirt, liquid, corrosive gases, or improper soldering.
  • Correct by cleaning, using sealed switches, or reviewing soldering methods.

• Contact Malfunction and Welding
  • Due to vibration, shock, or excessive load.
  • Correct by using switches with high contact force or inserting contact protection circuits.

• Insulation Degradation (Burning)
  • Caused by extreme heat or carbonized liquid.
  • Correct by using sealed switches or removing the heat source.

Mechanical Failures

• Operating Failure
  • Damaged actuators, foreign materials, or incorrect mounting cause it.
  • Correct using more robust actuators, cleaning the switch, or securing the installation.

• Actuator Low Durability
  • Due to improper operating methods or excessive speed.
  • Correct by changing the cam design or adjusting operating parameters.

• Mechanical Damage
  • It is caused by improper assembly, excessive force, or misaligned screws.
  • Correct by replacing the switch, adjusting torque, or ensuring correct screw installation.

• Terminal Damage
  • Due to excessive force or heat during wiring.
  • Correct by reducing soldering temperature or force during wiring.

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Pros & Cons

Pros:

High Precision: Micro switches provide accurate switching with minimal actuation force, making them ideal for applications requiring reliable performance.

Compact Size: Their small form allows integration into tight spaces within devices.

Durability: Designed to endure millions of operations, they offer long-lasting performance in various environments.

Versatile Applications: Suitable for consumer electronics, automotive systems, and industrial equipment, micro switches can fit diverse needs.

Cons:

Limited Load Capacity: Micro switches may not handle high current or voltage, restricting their use in specific applications.

Potential for Mechanical Failure: Mechanical components can wear out over time, leading to failure if not adequately maintained or selected for the application.

Sensitivity to Environmental Conditions: They can be affected by dust, moisture, and extreme temperatures if not adequately protected.

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History of Micro Switch

Micro switches, known for their precision and reliability, were invented in by Phillip Kenneth McGall in Freeport, Illinois. Developed initially to respond to minimal actuation force, the invention quickly led to the founding of the Micro Switch Company, later acquired by Honeywell and synonymous with these durable switches.

Throughout the s and s, advancements in materials improved their durability, leading to widespread use in consumer appliances and industrial equipment. The electronics boom of the s and s further miniaturized micro switches, reducing costs and opening up new applications in portable electronics and computing devices.

From the s to the present, as industries expanded globally, the demand for reliable micro switches increased, integrating them into automotive, telecommunications, and safety devices. In the 21st century, micro switches continue to evolve with innovative technology and IoT, expanding their presence in sophisticated applications across household and industrial machinery.

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Conclusion

In summary, micro switches are compact, reliable devices that operate on minimal force, making them essential in various applications, from automotive to industrial settings. Their design allows for high durability and precision, though they may have limitations in load capacity and environmental resilience. Understanding their construction, functionality, and types is crucial for selecting the appropriate switch for specific needs. The evolution of micro switches since their invention in reflects their growing importance in modern technology.

FAQ

1. What is a micro switch?

   A micro switch is a small, fast-acting switch with minimal force to make or break an electrical connection.

2. How does a micro switch work?

   It uses mechanical action from an actuator to open or close contacts, completing an electrical circuit.

3. What types of actuators do micro switches have?

   Common types include lever and roller actuators, each suitable for different applications.

4. How do I select the right micro switch for my application?

   Consider electrical ratings, actuator types, environmental conditions, and pole/throw counts.

5. Can micro switches be used in high-current applications?

   Most micro switches have limited load capacity and may not be suitable for high-current environments.

6. What are common failure modes for micro switches?

   Failures can include contact welding, insulation degradation, and actuator damage due to excessive force.

7. How can I troubleshoot a malfunctioning micro switch?

   Check for dirt or moisture on contacts, ensure proper mounting, and examine the actuator for damage.

8. Are micro switches sensitive to environmental conditions?

   Yes, they can be affected by dust, moisture, and extreme temperatures if not adequately protected.

9. What standards apply to micro switches?

   EN-1 standards outline safety and performance requirements for micro switches.

10. How do I wire a micro switch?

    Micro switches typically have three terminals: Common (C), Normally Open (NO), and Normally Closed (NC). Follow the circuit schematic for your application.

EagleElectrics is here to assist those seeking optimal solutions for industrial control needs. EagleElectrics provides push buttons, warning lights, control boxes, and electronic products.

We are committed to developing and manufacturing top-tier solutions that meet industrial demands. We welcome inquiries and are eager to help you find the perfect industrial solution tailored to your needs.

Contact us for more information!

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