Physical button old machinist style

Last crawled date: 4 years, 3 months ago

This is a real physical switch button with feedback.
derived from an old industrial grade momentary push button switch assembly.
Real switch feeling provided by heavy springloaded actuator and the click of the switch at the end of the travel.
Please take note, even if engaging a latching switch, the springloaded push button will return to the start position when unpressed.
THIS thing is not easy to adjust and assemble.
No, it is not just print out the parts and put them together.
When choosing the switch:
The requiered travel on its pusher must be no longer than 5.5mm (limited by the maximum travel of the push button, stay safe with 4.5mm)
If YOU want it easy, do not start making.
If you still want making the power switch thing, it could be changed in that way.
-Remove the spring from the button cap.
-Modify the pusher in designer CAD, make it longer, give the shaft an opening according to the shape of the power switch pusher.
For clarification: look at to the caps they can be had with, the did just that.
Than you have a permanently connected button cup.
Some pics are showing earlier made parts. Just to give you the idea.
Latest pic shows the monstrosity of the mains power switch assembly with the additionally supporting shim/ring.
The seen screws are way to long, but I had nothing else by hand.
Should I have made something with thread and nut instead?
Perhaps.
Allways do a dry run before you put it into the final position.
Check if it triggers the switch properly.
.
Now several configurations available.
Choose from momentary or latching push button using 8.5mm switches up to mains power switch.
.
Printing out is no hurdle.
But knowing the dimensions of the switche you have (size/travel) and making a fit with the dimensions defined by the switch body and pusher with its travel (start and end posiotn) can be challenging.
.
All parts printed are made using PETG.
Take PETG or ABS or something that does not break easily.
Huge benefit, it forgives when applying much force on the threads.
PLA might break easily.
Anytime recommended, predrill the holes. Use a fine file as a reamer.
.
The initial configurarion the switch body holds a small 8.5mmx8.5mm switch (momentary or latching) inside.
The mount mechanics allow mounting on plates from almost zero up to 22mm thickness.
See the pics.
Fot the small 8.5mm switch, they do exist in many configurations with different length of the pusher, with or without caps.
There is plenty of room to adapt it to the needed spacing (distance bottom of button pusher relatively with the top of the small switch).
Some tinkering needed sometimes.
.
Newest configuration:
The most tricky to adjust and assemble configuration.
Have attached the real mains powerswitch.
No LED's with this configuration planned.
In my case the screws holes on the switch metal bracket had to be drilled up to 3.5mm.
Assembling this configuration is not that hard on the desk but it will when you are going to put everything together from the inside of an existing tight case.
Mounting from inside against the the inner side of the front plate might pull you hairs.
You have been warned.
some files:
-mount cap with mountscrews for mains power switch i.e Rong Feng SS-160
width 18mm or smaller,
holes distance 20mm
pusher top to mount bracket top surface 18.8mm , if to long cut it the needed length
-washer 12mm
template making a shim for mounting against sensitive/brittle frontplates
-new cap covering the pcb.
-new cap covering the pcb with lugs for the mount screws.
-Preproduction file released, combines the formerly separated pusher skirt and the switch holder into one part.
Parts used:
-mini switches like "Push Button Switch ON/OFF DPDT 6Pin DIP 0.5A 30V DC 8.5x8.5mm"
-steel made spring, diameter 16-16.5mm 25mm length
-plastic screws 3x12-16mm, screw head no more than 2.5mm tall
-washer, diameter 12mm, thickness 1mm, hole size ca 3mm
-2*LED 5mm
-mount screws: 2x M3 20mm with nuts