When to Use Plunger Limit Switch？

Key Takeaway

A plunger limit switch is a type of switch that detects an object's presence or movement by using a small, spring-loaded plunger. When an object pushes against the plunger, the switch activates, opening or closing an electrical circuit. This triggers a response in the system, such as stopping a machine or adjusting a process. Plunger limit switches are known for their precise, reliable operation in industrial settings.

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These switches are commonly used in conveyor systems, assembly lines, and equipment doors. They can withstand shock and vibration, making them durable in challenging environments. Plunger limit switches are ideal for applications where objects need to be accurately detected and controlled, ensuring smooth and safe operation of machinery.

Advantages of Using Plunger Limit Switches for Position Sensing

Using plunger limit switches in industrial applications offers numerous advantages, particularly in terms of precision and reliability. Plunger switches are highly accurate, providing precise feedback on the position of machinery parts. This accuracy is crucial in automated systems where even a slight error can lead to issues like misalignment, product damage, or wasted materials.

Another key advantage is durability. Plunger limit switches are built to withstand the rigors of industrial environments, making them ideal for heavy-duty applications. Their robust design, often featuring materials resistant to wear and tear, ensures they last longer and require minimal maintenance. This durability translates into cost savings for businesses, as they don't need to frequently replace or repair the switches.

Furthermore, plunger limit switches offer versatility in application. They can be used in a wide range of industrial settings, from assembly lines to heavy machinery, and even in extreme conditions. Their straightforward mechanical operation means they are less susceptible to malfunctions caused by electrical interference or environmental factors. In systems where reliable position sensing is essential, plunger limit switches provide a cost-effective, dependable solution.

Proper installation of plunger limit switches is crucial to ensure their reliable performance. One of the primary considerations is alignment. The plunger should be positioned directly in line with the object that will activate it. Misalignment can lead to incomplete actuation, resulting in inconsistent performance or even premature wear on the switch.

Another important tip is to consider the operating environment. If the switch will be exposed to dust, moisture, or chemicals, it's advisable to use a model with a sealed housing. This will protect the internal components from damage and ensure longer-lasting performance. In cases where vibration is present, securing the switch with vibration-resistant mounts can prevent it from loosening over time.

Testing the actuation point during installation is also essential. Ensuring that the switch triggers at the correct point will provide accurate feedback to the control system, preventing unnecessary stops or delays in the process. Regular maintenance checks, such as cleaning and inspecting the plunger for wear, can help keep the switch in optimal condition. Following these installation guidelines can help extend the life of the switch and maintain reliable performance in demanding industrial environments.

There's probably not a day that goes by where you don't use or encounter a limit switch at home, or at your workplace.

Types of limit switches

There are 4 general types of limit switches:

1. Whisker

2. Roller

3. Lever

4. Plunger

Depending on the application, a limit switch may be a combination of 2 of the general types such as roller-lever.

What are limit switches?

A limit switch is an electromechanical device operated by a physical force applied to it by an object.

Limit switches are used to detect the presence or absence of an object.

These switches were originally used to define the limit of travel of an object, and as a result, they were named Limit Switch.

Limit switches applications

When you open the fridge door, a light comes on inside. How does that happen? Yes'. you guessed it! A limit switch is used to detect if the fridge door is open or closed.

Let's look at another application of a limit switch that you may encounter at home. On many overhead garage doors, there is a limit switch that stops the movement of the door when it reaches its fully opened position.

How Do Limit Switches Work?

Alright'.now that we've looked at a couple of limit switch applications where you might see them in action at home, let's have a closer look at the device itself.

Limit switches are electromechanical devices consisting of an actuator mechanically linked to an electrical switch.

When an object contacts the actuator, the switch will operate causing an electrical connection to make or break.

Configurations of limit switches

Limit switches are available in several switch configurations: Normally Open, Normally Closed, or one of each.

Symbols of limit switches

Depending on the origin of the electrical schematic, you may see limit switches drawn in different ways.

The International Electrotechnical Commission (IEC) and the National Electrical Manufacturers Association (NEMA) have slightly different symbols.

For more information, please visit Safety Limit Switch.

Microswitch

Let's have a look inside a microswitch that is a type of limit switch.

A microswitch has 2 limit switches operating together and sharing a common terminal. One limit switch is normally open and the other is normally closed.

To be technically correct, the switch configuration is Single Pole Double Throw, or commonly referred to as SPDT.

The dashed line indicates that both switches are mechanically connected and will operate at the same time.

Microswitch simple circuit

Alright, let's connect the microswitch to a lamp circuit. In the inactive state, the Red lamp is on as the device is not being operated by an object pushing on the trigger.

When the Trigger is pushed the device will activate, and the Green lamp will come on.

Limit switches in action

Now that you've seen the limit switch in action you are probably thinking about some of the applications where you have seen them in action.

For example, you might see limit switches operated by a container on an assembly line, or operated by a rotating machine part or by any number of other moving mechanical objects.

Limit switches could be used to count passing objects, or determining the position of a hydraulic cylinder.

Proximity sensor vs. limit switch

Limit switches are slowly starting to disappear from many industrial applications. They are being replaced by proximity sensors.

Unlike a limit switch, a proximity sensor has no mechanical moving parts.

A proximity sensor performs the switching action with electronic switches.

Limit switches will not completely disappear any time soon as they outshine their proximity switch counterpart in their ruggedness and reliable operation in difficult environments.

Generally speaking, limit switches are capable of handling much higher current values than proximity sensors.

You might want to review one of our other articles:

What is a Sensor? Different Types of Sensors, Applications

Summary

OK, let's review'

' There are 4 general types of limit switches: whisker, roller, lever, and plunger.

' Limit switches are electromechanical devices operated by a physical force applied to it by an object.

' A limit switch is an electromechanical device consisting of an actuator mechanically linked to an electrical switch.

' Limit switches are available in several switch configurations: Normally Open, Normally Closed, or one of each.

' Depending on the origin of the electrical schematic, you may see limit switches drawn in different ways.
' Limit switches are being replaced by proximity sensors in many applications.

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The RealPars Team

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