Indexing rotary switch

Information

  • Patent Grant
  • 6781070
  • Patent Number
    6,781,070
  • Date Filed
    Wednesday, January 29, 2003
    21 years ago
  • Date Issued
    Tuesday, August 24, 2004
    19 years ago
Abstract
A rotary indexing switch includes a base having a series of radially spaced stationary contact areas, and a rotary contact member having a rotary contact area. The stationary contact areas are defined by contact members engaged within passages in an insulating ring in a configuration dictated by specifications of the switch. The switch has a number of unique features, including mating engagement structure that drivingly engages actuator shafts of stacked switch assemblies; a spring for biasing the rotary contact member toward the stationary contact areas; a combination lift and detent arrangement for lifting the rotary contact areas away from the stationary contact areas and maintaining the rotary contact member in a contact position when the rotary contact areas are engaged with the stationary contact areas; a center contact selectively engageable with the base utilizing a cooperating engagement arrangement; and an integral enclosure wall which forms a dust shield.
Description




BACKGROUND AND SUMMARY OF THE INVENTION




This invention relates to an electrical switch, and more particularly to a rotary indexing electrical switch assembly.




An indexing rotary switch is employed in applications to control operating characteristics or parameters. In a representative application, an indexing rotary switch assembly is employed in an electrical arc welder to control current flow or other settings. A different electrical contact configuration is attained at each position of the rotary switch assembly, to set the parameters of operation.




A prior art rotary switch assembly utilizes a plastic injection molded base with a series of radially spaced contact members insert molded into the base. Each contact member defines a flat front surface which is flush with a front surface defined by the base, and a rearwardly or outwardly facing threaded passage. The base is configured such that the rearwardly or outwardly facing passage is exposed, and the lead of a cable is connected to the contact member via a threaded screw which extends into the passage. The prior art construction further involves use of a dust shield, formed separately from the base. The dust shield has a cylindrical wall which engages the outer peripheral edge of the base outwardly of the contact surfaces of the contact members. A rotary contact member is secured to and rotatable with an actuator shaft, which extends through a central opening formed in the base. In one version, a center contact is insert molded into the material of the base along with the outer contact members, and the rotary contact member establishes a connection between the center contact and one of the contact members. In another version in which the center contact is omitted, the rotary contact member selectively establishes a connection between selected pairs of the radially spaced contact members.




While the above-described construction has been found to function satisfactorily, it involves certain drawbacks in manufacture, assembly and operation. For example, insert molding of the outer contact members and the center contact is sensitive and labor intensive, in that the insert molded components must be manually placed within the mold in accurate positions since the contact positions cannot be altered after the insert molding process. This construction can lead to high rates of part rejection, since the contact positions are subject to very tight tolerances so as to ensure proper operation.




It is an object of the present invention to provide an indexing rotary contact switch having a number of design, manufacturing and operating enhancements as compared to prior art indexing rotary contact switches. It is a further object of the invention to provide such a rotary contact switch having a reduced cost of manufacture and which reduces the rate of part rejection. Yet another object of the invention is to provide such a rotary contact switch which is capable of being produced in a wide range of switch contact configurations utilizing common parts. A still further object of the invention is to provide such a switch assembly which entails use of a relatively small number of components so as to reduce manufacturing costs and increase reliability and quality. Yet another object of the invention is to provide such a rotary contact switch which eliminates insert molding of the contacts with the base. A still further object of the invention is to provide such a rotary contact switch which is relatively simple in its design and manufacture, yet which entails a number of advantages in part manufacture, assembly and overall operation.




In accordance with the invention, an indexing rotary contact switch assembly includes a base having a series of radially spaced stationary contact areas, and a rotary contact arrangement mounted for rotary movement relative to the base. The rotary contact arrangement includes at least one rotary contact area, and is movable to a plurality of contact positions in which the rotary contact area of the rotary contact arrangement engages at least one of the stationary contact areas of the base.




The base is preferably formed so as to include a series of radially spaced passages, and the stationary contact areas are defined by contact members received within certain passages in the base. The contact members are engaged within the passages according to the desired configuration of the switch assembly, so as to place the contact areas in certain locations on the base. The contact members are secured to the base after production of the base, so that the same base can be used to form a base assembly with a variety of contact configurations. In one form, the base is formed so as to define a generally circular opening, and the passages are formed in an insulating ring that is engaged within the generally circular opening. The insulating ring is configured to close the opening. In this manner, the forward portion of the base, within which the stationary contact areas and the rotary contact arrangement are located, is isolated from the environment in which the switch assembly is employed, such as within the interior of the housing of an electrical arc welder or the like. The insulating ring may be formed to have any number of openings in any desired configuration, to provide flexibility in the design and manufacture of the switch assembly.




A combination lift and detent arrangement is interposed between the base and the rotary contact arrangement. The lift and detent arrangement functions to lift the rotary contact area away from the stationary contact areas of the base upon rotation of the rotary contact arrangement between the stationary contact areas, and releasably maintains the rotary contact arrangement in a contact position in which the rotary contact area is in contact with at least one of the stationary contact areas of the base. The lift and detent arrangement preferably includes ramp structure formed integrally with the base, and at least one lift member associated with the rotary contact arrangement. The lift member engages the ramp structure upon rotation of the rotary contact arrangement to lift the rotary contact area away from the base, and engages the ramp structure when the rotary contact member is stationary so as to maintain the rotary contact arrangement in the contact position. The ramp structure may be in the form of a series of individual radially spaced ramps formed integrally with the base, and each ramp is preferably located so as to correspond in location to one of the stationary contact areas.




The switch assembly may include a center contact selectively engageable with the base and defining a stationary center contact area. The rotary contact arrangement includes a rotary inner contact area engageable with the stationary center contact area. The center contact and the base include cooperating engagement structure for engaging the center contact with the base subsequent to manufacture of the base. The center contact includes an opening through which an actuator shaft associated with the rotary contact arrangement extends. The cooperating engagement structure may be in the form of a fastener engaged between the center contact and the base on one side of the opening, in combination with a tab formed on the center contact and engageable within an opening in the base, on the opposite side of the opening.




The actuator shaft of the rotary contact arrangement includes a forward section located forwardly of the base and a rearward section located rearwardly of the base. The forward section of the actuator shaft is adapted to mount an actuator handle which is manually engageable by a user for imparting rotation to the rotary contact arrangement. A second rotary indexing switch assembly is adapted for mounting rearwardly of the base of the first-mentioned switch assembly, and the respective switch assemblies include respective first and second actuator shafts. The actuator shafts are similarly constructed, and the forward section of the second actuator shaft is adapted to be received within an opening in the rearward section of the first actuator shaft. Mating engagement structure is interposed between the first and second actuator shafts, for imparting rotation to the second actuator shaft upon rotation of the first actuator shaft. The mating engagement structure may be in the form of radially spaced axially extending splines which function to rotate the second actuator shaft upon rotation of the first actuator shaft. A positioning arrangement, such as a missing spline, may be provided for positioning the second actuator shaft in a predetermined orientation relative to the first actuator shaft.




The switch assembly further includes a conical spring arrangement interposed between the actuator shaft and the rotary contact member, for biasing the rotary contact member toward the radially spaced stationary contact areas of the base. The conical spring defines a passage through which the actuator shaft extends, and includes a first end spaced from the rotary contact member and a second end in engagement with the rotary contact member. The second end has a transverse dimension greater than the first end. A spring retaining member, such as a snap ring, is engaged with the actuator shaft for engaging the first end of the conical spring, to compress the spring and to bias the contact member toward the stationary contact areas of the base.




The base preferably has an integrally formed enclosure wall which extends from the surface of the base containing the stationary contact areas. The contact areas are contained in a contact surface defined by the base, and the enclosure wall cooperates with the contact surface to define an internal cavity within which the stationary contact areas and the rotary contact member are located. The enclosure wall is adapted to engage a planar member to which the switch assembly is mounted, such as the wall of the welder housing, for enclosing the internal cavity defined by the enclosure wall and the contact surface.




The switch assembly further includes a selectably positionable stop arrangement interposed between the rotary contact arrangement and the base for controlling the range of rotary movement of the rotary contact arrangement relative to the base. The stop arrangement includes a pair of stop members which are engageable with the base in varying locations. The actuator shaft includes an engagement member which engages the stop members upon rotation, to control the range of rotary movement of the rotary contact arrangement.




The base and the actuator shaft can be employed to mount either a first contact member or a second contact member to the rotary switch assembly. The first contact member includes a first contact arrangement adapted to engage the stationary contact areas in a first configuration, and the second contact member includes a second contact arrangement adapted to engage the stationary contact members in a second configuration. A differently configured switch assembly is attained by engaging either the first contact member or the second contact member with the actuator shaft, and rotatably mounting the selected contact member and the actuator shaft to the base.




The invention further contemplates a method of producing a base having a selectively configurable stationary contact arrangement, substantially in accordance with the foregoing summary.




The various features of the invention may be employed independently, and each is capable of improving an aspect of operation or assembly of a rotary indexing switch assembly. In a preferred form, the various aspects can be employed in combination to provide a rotary indexing switch assembly with significant advantages in assembly and operation.




Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings.











BRIEF DESCRIPTION OF THE DRAWINGS




The drawings illustrate the best mode presently contemplated of carrying out the invention.




In the drawings:





FIG. 1

is an isometric view of an electrical arc welder incorporating the indexing rotary switch assembly of the present invention;





FIG. 2

is an isometric view of the indexing rotary switch assembly incorporated into the welder of

FIG. 1

, showing the forward area of the switch assembly;





FIG. 3

is an isometric view of the indexing rotary switch assembly of

FIG. 2

, showing the rearward portion of the switch assembly;





FIG. 4

is a section view taken along line


4





4


of

FIG. 1

;





FIG. 5

is a front elevation view of the switch assembly of

FIGS. 2-4

;





FIG. 6

is a rear elevation view of the switch assembly of

FIGS. 2-4

;





FIG. 7

is a section view taken along line


7





7


of

FIG. 5

;





FIG. 8

is a partial elevation view showing engagement of a pair of mounting bosses associated with adjacent switch assemblies as illustrated in

FIGS. 2-6

;





FIGS. 9 and 10

are elevation views of the actuator shaft incorporated in the rotary switch assembly of

FIGS. 2-7

;





FIG. 11

is a section view taken along line


11





11


of

FIG. 9

;





FIG. 12

is a section view taken along line


12





12


of

FIG. 9

;





FIG. 13

is a plan view of a rotary contact member incorporated into the rotary switch assembly of

FIGS. 2-7

;





FIG. 14

is a side elevation view of a center contact member incorporated into the rotary switch assembly of

FIGS. 2-7

;





FIGS. 15 and 16

are enlarged partial section views of an outer peripheral contact portion incorporated into the base of the switch assembly of

FIGS. 2-7

;





FIG. 17

is a partial front elevation view similar to

FIG. 5

, showing the rotary contact member moved to a position between adjacent stationary contact areas of the base;





FIG. 18

is a partial section view taken along line


18





18


of

FIG. 17

;





FIG. 19

is a partial section view taken along line


19





19


of

FIG. 5

;





FIG. 20

is an enlarged partial section view illustrating a portion of the rotary contact member shown in

FIGS. 18 and 19

moved into engagement with a ramp member forming a part of a lift and detent arrangement incorporated into the rotary switch assembly of

FIGS. 2-7

;





FIG. 21

is an isometric view similar to

FIG. 2

, showing another embodiment of a rotary contact arrangement incorporated into the rotary switch assembly;





FIG. 22

is a front elevation view of the rotary switch assembly of

FIG. 21

;





FIG. 23

is an elevation view illustrating the rotary contact member incorporated into the rotary switch assembly of

FIG. 21

;





FIG. 24

is a partial section view taken along line


24





24


of

FIG. 22

;





FIG. 25

is a front elevation view of a base incorporated into the switch assembly of

FIGS. 2-4

;





FIG. 26

is a rear elevation view of the switch assembly base of

FIG. 25

;





FIG. 27

is an isometric view of an insulating ring adapted for use in combination with the base of

FIG. 25

, for incorporation into the switch assembly of

FIGS. 2-4

;





FIG. 28

is a front elevation view of the insulating ring of

FIG. 27

;





FIG. 29

is a rear elevation view of the insulating ring of

FIG. 28

; and





FIG. 30

is a section view taken along line


30





30


of FIG.


25


.











DETAILED DESCRIPTION OF THE INVENTION





FIG. 1

illustrates an electrical arc welder


30


incorporating a rotary indexing switch assembly


32


, constructed according to the invention, for varying the settings of welder


30


. Welder


30


includes a face plate


34


to which rotary indexing switch assembly


32


is mounted, in a conventional manner. Switch assembly


32


includes a switch handle


36


located exteriorly of face plate


34


, and the remaining components of switch assembly


32


are located interiorly of face plate


34


. The general construction and operation of welder


30


is known in the art, and representatively welder


30


may be a welder such as is available from the Miller Electric Mfg. Co. of Appleton, Wis. under its designation Bobcat 250NT, 225NT or 225D.




Referring to

FIG. 2

, switch assembly


32


generally includes a base member


38


to which a series of radially spaced contact members


40


are mounted, a rotary contact member


42


, and an operating assembly


44


which includes a central actuator shaft


46


and switch handle


36


.




As shown in

FIGS. 2-4

, a series of mounting bosses


48


are formed integrally with base member


38


. Each mounting boss


48


terminates in a forward end


50


within which a slot


52


is formed. A passage


54


extends inwardly from slot


52


. Fasteners


56


, such as screws, extend through face plate


34


and into passages


54


for securing base member


38


, and thereby switch assembly


32


, in position within the interior of welder


30


. At its rear end, each mounting boss


48


defines a tab


58


which is aligned with the slot


52


formed in forward end


50


. Passage


54


extends throughout the length of each mounting boss


48


, and emerges from the rear end of each mounting boss


48


to define an opening in tab


58


.




As shown in

FIGS. 5 and 6

, base member


38


includes a main body section having a front


60


which includes exposed contact members


40


, as well as an oppositely facing rear


62


. Base member


38


includes an integral forwardly extending side wall


64


, which extends forwardly from front


60


. The edge of side wall


64


engages the inner surface of face plate


34


, as shown in

FIG. 4

, to create a dust shield preventing entry of dust or other contaminants into the interior defined by side wall


64


in combination with front


60


of base member


38


.




Referring to

FIGS. 5-7

and


25


-


30


, base member


38


is constructed of an insulating ring


61


that is received within a circular opening


63


formed in front


60


of base member


38


. Base member


38


includes a series of radially spaced apart connectors


65


that extend across opening


63


to interconnect the inner and outer portions or base member


38


. The rear of insulating ring


61


includes radially spaced recesses


67


that are configured to receive connectors


65


when insulating ring


61


is received within opening


63


. In this manner, engagement of connectors


65


within recesses


67


functions to maintain insulating ring


61


in engagement with base member


38


such that insulating ring


61


is prevented from rotation relative to base member


38


.




The front of insulating ring


61


includes a series of non-circular recesses


69


, which may representatively be hexagonal in shape. Ring


61


further defines a series of radially spaced rearwardly extending contact receivers


68


, each of which defines a rearwardly facing surface


70


. Each of radially spaced recesses


67


is located between a pair of adjacent contact receivers


68


. At its center, base member rear


62


includes a lobed stop section


74


which includes a rearwardly facing surface


76


and a series of passages


78


which extend forwardly from rearwardly facing surface


76


. A pair of stop members, in the form of threaded screws


80


, are engaged within a selected pair of passages


78


.




Actuator shaft


46


extends through a central passage


82


defined by base member


38


. At its rear end, actuator shaft


46


defines a head


84


having a transverse dimension greater than central passage


82


. Head


84


has a rear surface


86


and a side surface


88


. An outwardly extending stop tab


90


extends from side surface


88


, and a forwardly extending splined passage


92


extends forwardly from rear surface


86


. Head


84


further defines a forwardly facing shoulder


94


which engages rearwardly facing surface


76


of stop section


74


. Stop tab


90


extends radially outwardly from head side surface


88


so as to overlap passages


78


, such that stop tab


90


is engageable with stop screws


80


, as will later be explained.




Forwardly of rear head


84


, actuator shaft


46


includes a cylindrical mounting section


96


which is received within central passage


82


defined by base member


38


, and a reduced diameter forward section


98


which terminates in an externally splined forward stem


100


to which switch handle


36


is mounted. For reasons to be explained, forward section


98


of actuator shaft


46


includes a square section


99


located adjacent the forward end of mounting section


96


. Handle


36


includes a hub


104


defining a rearwardly facing internally splined passage


106


, which mates with externally splined forward stem


100


of actuator shaft


46


. An axial passage


108


is formed in forward stem


100


, and a threaded fastener, such as a screw


110


, extends through an aperture


112


formed in hub


104


and into engagement with passage


108


, for non-rotatably mounting handle


36


to actuator shaft


46


.




With reference to

FIGS. 2-7

,


18


,


19


,


28


and


29


, each contact member


40


includes a forward head section


114


defining an exposed front surface


116


. Recesses


69


, which extend inwardly from the front surface of insulating ring


61


, have a shape corresponding to that of contact head section


114


. Each recess


69


includes an outer shoulder


122


. Each recess


69


communicates with an internal passage, shown at


124


, defined by each contact receiver


68


. The outer area of each contact head section


114


engages shoulder


122


of recess


69


, and each contact


40


further defines a body section


126


received within contact receiver passage


124


. A shoulder


127


is located at the rearward end of each body section


126


, and a threaded shank


128


extends rearwardly from shoulder


127


.




As shown in

FIG. 3

, a series of bridging rear contact members or buss bars


129


are connected between selected ones of contact members


40


. Rear contact members


129


function to interconnect selected cable assemblies, shown at


130


, which in turn provide the input and output from switch assembly


32


, with each selected set of interconnected cable assemblies


130


providing predetermined settings, parameters or operating characteristics of welder


30


. In the drawings, rear contact members


129


are shown as being located radially inwardly of contact members


40


. It is also understood that rear contact members


129


may be located radially outwardly of contact members


40


.




Base member


38


is preferably formed of any satisfactory material, such as thermoplastic or thermoset material in any satisfactory process, such as by injection molding. Contact members


40


are formed of an electrically conductive material separately from base member


38


and may be engaged with base member


38


subsequent to formation of base member


38


, by inserting contact head section


114


and body section


126


into recess


69


and passage


124


, respectively, until the rear edge of head section


114


engages shoulder


122


. A cable assembly, such as


130


, is then engaged with each contact member


40


in predetermined locations according to the desired configuration of switch assembly


32


. Each cable assembly


130


includes a cable


132


and a sleeve


134


engaged with the end of cable


132


in a manner as is known. At its outer end, each sleeve


134


is interconnected with a flat contact section


136


, which includes an opening through which contact member shank


128


extends. In the drawings, each sleeve


134


is illustrated as extending radially outwardly from its associated flat contact section


136


. In another arrangement, a bend is located between each sleeve


134


and its associated flat contact section


136


, such that sleeve


134


extends perpendicularly in a rearward direction from its associated flat contact section


134


. As shown in

FIG. 7

, contact section


136


engages rearwardly facing shoulder


127


of contact member


40


defined between body section


126


and shank


128


. A nut


138


is threaded onto contact member shank


128


, into engagement with sleeve contact section


136


, for establishing an electrical connection between cable


132


and contact member


40


.




Referring to

FIGS. 5 and 7

, a center contact


140


is engaged with base member


38


. Center contact


140


defines a central opening


142


and an annular contact section


144


which is received within a correspondingly shaped recess formed in front base surface


118


. Center contact


140


further includes an outward extension


146


. Outward extension


146


is engaged with the outwardly facing surface of a contact member


148


, which includes a threaded passage in alignment with an opening


150


formed in outward extension


146


. A connector, in the form of a screw


152


, is engaged with outward extension


146


of center contact


140


. Screw


152


includes a head


153


and a threaded shank


154


. The threads of shank


154


are engaged within the threaded passage in contact member


148


to establish electrical contact between center contact


140


and contact member


148


via engagement of screw head


153


with the outwardly facing surface of outward extension


146


of center contact


140


. In a manner similar to that described with respect to contact member


40


, a cable assembly


130


is engaged with contact member


148


through engagement of a cable assembly contact section


136


sandwiched between the end of contact member


148


and a nut


138


which is threadedly engaged with shank


154


, to establish electrical contact of a cable


132


with center contact


140


through outward extension


146


.




Center contact


140


further includes an outwardly extending engagement tab


155


(

FIGS. 6

,


7


), which extends opposite outward extension


146


. A recess


157


is formed in rear


62


of base member


38


, and terminates rearwardly of front base surface


118


. Engagement tab


155


extends into recess


157


below front base surface


118


. With this construction, center contact


140


is maintained in engagement with base member


38


by engagement tab


155


in combination with screw


152


.




Rotary contact member


42


is engaged with actuator shaft


46


so as to be rotatable with actuator shaft


46


. Referring to

FIG. 13

, rotary contact member


42


includes a square opening


156


, and square section


99


of actuator shaft


46


has a square cross-section corresponding to the shape of opening


156


. In this manner, rotation of actuator shaft


46


causes pivoting movement of rotary contact member


42


relative to base member


38


, about a pivot axis defined by the longitudinal axis of actuator shaft


46


.




Rotary contact member


42


further includes an outer contact depression


158


and an inner contact depression


160


. Outer contact depression


158


overlies front surfaces


116


of contact member head sections


114


, and inner contact depression


160


overlies annular contact section


144


of center contact


140


. A tapered coil spring


162


defines an enlarged rearward end which is seated within an insulating spacer


163


(

FIG. 7

) that bears against the forward surface of rotary contact member


42


. Spring


162


further defines a narrowed forward end which engages a snap ring


164


received within a groove


166


formed in actuator shaft forward section


98


. With this construction, actuator shaft


46


is retained on base member


38


for pivoting movement, and spring


162


provides a biasing force urging rotary contact member


42


toward front face surface


118


. In this manner, inner contact depression


160


is urged by spring


162


into engagement with the forward surface of annular contact section


144


, and outer contact depression


158


is urged toward head section front surfaces


116


.




Rotary contact member


42


further includes a pair of arcuate outer recesses


168


located one on either side of outer contact depression


158


. At its outer end, rotary contact member


42


is formed with an outwardly facing recess


170


, and a pair of engagement wings


172


located one on either side of recess


170


. As shown in

FIG. 5

, arcuate outer recesses


168


are oriented and sized such that, when outer contact depression


158


is aligned with and engaged with one of contact members


40


, the adjacent contact members


40


are in alignment with recesses


168


so that no portions of rotary contact member


42


overlie the adjacent contact members


40


. Rotary contact member


42


is sized such that wings


172


are located closely adjacent the inside surface of side wall


64


, at the intersection between side wall


64


and front base surface


118


.




Referring to

FIG. 5

, front


60


of base member


38


further includes a series of ramps


174


located at the intersection of side wall


64


with front base surface


118


. Each ramp


174


is located outwardly of one of contact members


40


. Ramps


174


are formed integrally with side wall


64


and front base surface


118


. As shown in

FIGS. 18 and 19

, each ramp


174


includes a flat outer surface


176


and a pair of angled ramp surfaces


178


extending in opposite directions from outer surface


176


, terminating in a pair of side edges


180


, each of which extends between the outer end of one of ramps


178


and front base surface


118


.




In operation, switch assembly


32


functions as follows to control the settings of arc welder


30


, wherein an electrical current path is established from cable assembly


130


to contact member


40


, from contact member


40


to rotary contact member


42


, from rotary contact member


42


to center contact


140


, from center contact


140


to contact member


148


, and from contact member


148


to cable assembly


130


. In order to change the settings of arc welder


30


, the user manually applies a rotary force to switch handle


36


to move switch assembly


32


from a position in which rotary contact member


42


moves from engagement with one of contact members


40


to another of contact members


40


. Rotation of switch handle


36


is transferred through engagement of switch handle splined passage


106


with splined forward stem


100


, to rotate actuator shaft


46


. This in turn causes rotation of rotary actuator member


42


through engagement of actuator shaft forward section


98


with square opening


156


in rotary contact member


42


. As rotary contact member


42


is rotated in this manner, the rear surface of outer contact depression


158


slides along front surface


116


of contact member head sections


114


. When the rear surface of outer contact depression


158


reaches the edge of front surface


116


, one of wings


172


comes into engagement with the ramp surface


178


of a ramp


174


located at the adjacent contact member


40


, as shown in FIG.


20


. Continued rotary movement of rotary contact member


42


causes the wing


172


to move onto ramp outer surface


176


. Simultaneously, the opposite wing


172


comes into engagement with a ramp surface


178


of the ramp


174


located at the contact member


40


which rotary contact member


42


is being moved away from. This engagement of wings


172


with ramps


174


functions to lift the outer end of rotary contact member


42


away from front base surface


118


against the force of spring


162


, and thereby to lift the rear surface of outer contact depression


158


upwardly out of engagement with contact member head section


114


. Continued rotary movement of actuator shaft


46


through switch handle


36


places rotary contact member


42


in a position as shown in

FIG. 18

, wherein outer contact depression


158


is located midway between adjacent contact members


40


. As rotation of rotary contact member


42


continues, wings


172


continue to move along ramp outer surfaces


176


and come into position over the opposite ramp surfaces


178


. The force of coil spring


162


forces rotary contact member


42


rearwardly toward front base surface


118


, which functions to maintain inner contact depression


160


against the forwardly facing surface of annular contact section


144


of center contact


140


, and simultaneously causes the outer end of rotary contact member


42


to move forwardly as wings


172


move along ramp surfaces


178


. Rotary movement of rotary contact member


42


continues until wings


172


are disengaged from ramps


174


, as shown in

FIG. 19

, which results in the rear surface of outer contact depression


158


coining into engagement with front surface


116


of contact head section


114


of the adjacent contact member


40


, under the influence of coil spring


162


.




Wings


172


and ramps


174


are positioned and constructed so as to provide a detent for maintaining outer contact depression


158


in engagement with front surface


116


of contact member head section


114


. That is, any rotation of rotary contact member


42


away from its engaged position of

FIG. 19

results in engagement of one of wings


172


with the ends of ramp surfaces


178


of a pair of adjacent ramps


174


, such that subsequent additional rotation is resisted by the rearward force exerted on rotary contact member


42


by spring


162


. This prevents rotary contact member


42


from being moved out of contact with the selected contact member


40


in response to an inadvertent movement of switch handle


36


. The size of recess


170


and the orientation of wings


172


are such that the rear surface of outer contact depression


158


remains in engagement with head section front surface


116


when wings


172


initially contact ramp surfaces


178


in this manner. Any further rotation of rotary contact member


42


beyond this point results in wings


172


riding along ramp surfaces


178


, which lifts the outer end of rotary contact member


42


away from front base surface


118


to disengage outer contact depression


158


from front surface


116


. With this construction, rotary contact member


42


has a positive detent at each incremental engaged position, which eliminates any uncertainty on the part of the user as to whether rotary contact member


42


is engaged with a contact member


40


when switch handle


36


is moved to a desired setting. The user continues application of the rotary force to switch handle


36


until the desired setting is attained. At each setting of switch assembly


32


, the detent arrangement provided by wings


172


and ramps


174


must be overcome by the rotary force applied by the user, until the desired switch setting is attained.




As shown in

FIGS. 3 and 6

, stop screws


80


are positioned relative to stop section


74


so as to control the range of movement of rotary switch member


42


. Stop tab


90


defined by head


84


at the rear end of actuator shaft


46


engages stop screws


80


, to provide a positive stop against rotation of actuator shaft


46


when certain positions of rotary contact member


42


are attained. In a typical application, stop screws


80


are placed so as to prevent rotary contact member


42


from being moved into alignment with outward extension


146


of center contact


140


and its associated connector


152


. Additional contact positions on either side of outward extension


146


may be unused according to the number of available settings for switch assembly


32


and the specifications of welder


30


, and stop screws


80


are positioned in appropriate ones of passages


78


so as to provide the desired range of movement of rotary contact member


42


. In an application in which all available positions are employed, a single stop screw,


80


may be utilized and placed in the passage


78


corresponding to center contact outward extension


146


, so that rotary contact member


42


can be placed in all available contact positions other than outward extension


146


.




As shown in

FIGS. 4 and 7

, the switch assemblies


32


can be stacked one on top of another, such that an additional switch assembly


32




a


is employed in combination with the switch assembly


32


mounted to face plate


34


and with which switch handle


36


is engaged. Switch assembly


32




a


has the same general construction and operation as switch assembly


32


, with the exception that there is no switch handle


36


for second switch assembly


32




a


. Instead, the splined forward stem


100


of the actuator shaft of switch assembly


32




a


is engaged within the splined passage


92


of the actuator shaft of switch assembly


32


, such that the rotary contact members of the switch assemblies


32


and


32




a


rotate together. Alternatively, switch assembly


32




a


may have any other satisfactory rotary switch configuration. In a stacked application, second switch assembly


32




a


is positioned rearwardly of first switch assembly


32


. Mounting bosses


48




a


of second switch assembly


32




a


are aligned with mounting bosses


48


of first switch assembly


32


(as shown in FIG.


8


), and the tab


58


defined by the rearward end of each mounting boss


48


is received within the forwardly facing slot


52




a


of the corresponding mounting boss


48




a


. The base member


38




a


of second switch assembly


32




a


is thus aligned with base member


38


of first switch assembly


32


. To ensure proper alignment between actuator shaft


46


of first switch assembly


32


and the actuator shaft of second switch assembly


32




a


, the splines of passage


92


are formed such that a solid area


184


(

FIG. 11

) is located in an area between a pair of splines, wherein a spline would normally be located. Actuator shaft forward stem


100




a


includes a corresponding blank area


186




a


(FIG.


12


), which mates with solid area


184


to ensure that actuator shaft


46




a


of second switch assembly


32




a


is in a desired orientation relative to actuator shaft


46


of first switch assembly


32


. The splined engagement of actuator shaft


46




a


with actuator shaft


46


ensures that the switch rotary contact members, such as


42


, rotate together when handle


36


is rotated to change the settings of welder


30


.




When second switch assembly


32




a


is installed, the length of each fastener


56


is sufficient to enable the fastener shank to pass completely through mounting boss passage


54


and into engagement with the passage


54




a


of one of mounting bosses


48




a


of second switch assembly


32




a


. This functions to draw second switch assembly


32




a


toward first switch assembly


32


, to secure first switch assembly


32


and second switch assembly


32




a


together.




Referring to

FIG. 15

, each contact member


40


is pushed into place such that the irregular shape of head


114


is oriented in alignment with the corresponding irregular shape of recess


69


, and contact member


40


is then pushed rearwardly to press contact member body section


126


into contact-receiving passage


124


and the rearward edge of head


114


into engagement with shoulder


122


. During initial assembly of switch assembly


32


, an adhesive may be used to maintain contact members


40


in engagement with insulating ring


61


. In final assembly, a nut, such as


138


, is engaged with contact member shank


128


and tightened down toward the rearwardly facing shoulder of contact member body section


126


, to clamp sleeve contact section


136


into engagement with rearwardly facing shoulder


127


of contact member body section


126


.





FIGS. 21-24

illustrate an alternative switch assembly


32


′. The majority of the components of switch assembly


32


′ are the same as described with respect to switch assembly


32


, and like reference characters will be used to facilitate clarity.




Switch assembly


32


′ includes base member


38


, contact members


40


, actuator shaft


46


and switch handle


36


, in the same manner as switch assembly


32


. In switch assembly


32


′, center contact


140


is eliminated. Switch assembly


32


′ includes a bridging rotary contact member


204


engaged with actuator shaft


46


and rotatable in response to rotation of actuator shaft


46


through switch handle


36


. In the same manner as rotary contact member


42


, coil spring


162


urges bridging rotary contact member


204


rearwardly toward front base surface


118


.




Bridging rotary contact member


204


includes a central area


206


having a square opening


208


which has a shape corresponding to that of actuator shaft forward section


98


. Coil spring


162


bears against central area


206


to urge bridging rotary contact member


204


rearwardly. A pair of contact sections


210


are located one on either side of central area


206


. Each contact section


210


includes a pair of depending contact mounting fingers


212


(

FIG. 24

) terminating in inwardly extending tabs


214


. Opposite ends of a bridging contact


216


are engaged by tabs


214


, to mount bridging contact


216


to rotary contact member


204


. Each contact section


210


includes a depending protrusion


218


extending downwardly from a rear surface


220


. Bridging contact


216


has a mating recess


222


within which protrusion


218


is received. With this construction, bridging contact


216


is moved inwardly into engagement with tabs


214


, between fingers


212


, and deflects slightly until protrusion


218


is received within recess


222


, for securely maintaining bridging contact


216


in engagement with its associated contact section


210


. Alternatively, a retainer such as an e-ring may be employed to maintain bridging contact


216


in engagement with rotary contact member


204


. Each bridging contact


216


includes a pair of laterally spaced contact depressions


224


, which have a center-to-center spacing the same as that of contact members


40


.




A depending cam member


226


is located at the outer end of each contact section


210


. Each cam member


226


has a rear surface


228


and a pair of ramp-like cam surfaces


230


. The width of each cam member


226


is slightly smaller than the transverse dimension of the space between adjacent ramps


174


of base member


38


.




In operation, bridging rotary contact member


204


functions to establish contact between opposite pairs of adjacent contact members


40


or a single pair of adjacent contact members


40


. Bridging rotary contact member


204


is movable in an indexing fashion so as to establish electrical contact between selected adjacent pairs of contact members


40


according to the desired setting of switch assembly


32


′. When bridging rotary contact member


204


is in an operative position, as shown in

FIG. 24

, contact depressions


224


engage front surfaces


116


of adjacent contact head sections


114


, to establish contact therebetween through bridging contact


216


. When it is desired to change the settings of welder


30


, the user manually rotates switch handle


36


, to impart rotation to bridging rotary contact member


204


through actuator shaft


46


. As contact member


204


is rotated, one of cam surfaces


230


rides along one of ramp surfaces


174


, to lift contact member


204


upwardly away from front base surface


118


, and to move contact depressions


224


out of engagement with head section front surfaces


116


against the force of coil spring


162


. At each increment of rotation of contact member


204


, spring


162


forces contact member


204


rearwardly toward front base surface


118


, and cam member surfaces


228


,


230


engage surfaces


176


,


178


of ramps


174


to facilitate repeated lifting of contact member


204


during such rotation. When the desired location of contact member


204


is attained, further application of manual rotary force to switch handle


36


is discontinued, and contact member


204


is positioned as shown in

FIG. 24

to establish an electrical connection between adjacent contact members


40


. When rotary contact member


204


is in its engaged position as shown, the edges of cam surfaces


230


engage the edges of ramp surfaces


178


, to provide a positive detent against further rotation of rotary contact member


204


until application of a subsequent rotary force to switch handle


36


.




The invention has been shown and described with various details, and it is understood that alternative configurations are possible. For example, details of the driving configuration between switch handle


36


, actuator shaft


46


and rotary contact members


42


,


204


may vary. Switch handle


36


may be engaged with actuator shaft


46


utilizing a driving connection other than mating splines, such as any type of irregular mating cross-section. The same holds true for the square mating engagement between actuator shaft


46


and contact members


42


,


204


, which may be in the form of any type of irregular cross-section or other type of driving connection. Further, the provision of contact depressions on rotary contact member


42


and bridging contacts


216


may be replaced with other types of protruding contact structure, which may or may not be integrally formed with the contact member. Contact member head sections


114


are illustrated with front surfaces


116


being flush with front base surface


118


, whereas the contact surfaces of contact members


40


may be in any type of flush, recessed or protruding configuration. In addition, center contact


140


has been illustrated as being retained in place using an offset bent section in combination with a connector, and other types of retainer arrangements may be employed, such as recessed connectors or mounting other than in a flush-mounted manner. The tab-and-slot connection of mounting bosses in a stacked switch configuration may be replaced with any type of engagement arrangement providing mating engagement structure. While fasteners such as screws are shown as being receivable within passages


54


for mounting switch member


32


and adjacent switch member


32




a


, it is understood that any other type of mounting arrangement may be employed, such as separate fasteners mounting one switch to the housing of welder


30


and the second switch assembly to the first. Further, other types of removable and selectively engageable stop structure may be employed for limiting pivoting movement of the actuator shaft in place of engagement of stop screws


80


within passages


78


.




In addition, the interaction of the various ramps and cam surfaces, which lift the rotary contact member upon rotation and which provide a positive detent against rotation, may be replaced with other similar structure on the base and contact member, and is not limited to the particular configuration illustrated and described. For example, ramps and cam surfaces may be located inwardly of the contact members rather than outwardly.




Further, it is understood that the features of insulating ring


61


may be incorporated into base member


38


, and vice versa.




In another embodiment, the contact member passages may be initially closed via flashed-over transverse walls that initially close the contact member passages. In this arrangement, the heads of the contact members are pushed through selected ones of the flashed-over wall to install the contact members. In the event a contact passage does not receive a contact member, the flashed-over wall remains intact to maintain the passage closed. It is understood that other types of selectively openable arrangements may also be employed. For example, contact-receiving passages


124


may be formed so as to be fully open, and removable plugs may be utilized for closing off selected passages


124


according to the design and specifications of the switch.




As can be appreciated, the same switch base member can be employed for producing a variety of switch assemblies having different specifications and operation, according to the number and placement of the contact members, the bus bars and the type of rotary actuator member employed. The invention thus provides significant cost savings in manufacture and parts inventory, and provides a great deal of flexibility in the type of switch assembly being produced. In addition, replacement of defective components in the switch assembly is significantly easier than in the past, wherein many of the contact components were embedded or insert molded into the material of the base. The individual components can be easily replaced as desired, for repair or retrofitting so as to alter the switch configuration or specifications.




In addition to the above, various alternatives and embodiments are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention.



Claims
  • 1. A rotary indexing switch assembly, comprising:a base having a series of radially spaced stationary contact areas; a rotary contact arrangement mounted for rotary movement relative to the base, wherein the rotary contact arrangement includes at least one rotary contact area, wherein the rotary contact arrangement is movable to a plurality of contact positions in which the rotary contact area of the rotary contact arrangement engages at least one of the stationary contact areas of the base; wherein the base includes a series of radially spaced passages, and wherein the stationary contact areas are defined by a plurality of contact members, wherein each of the contact members is received within one of the passages in the base subsequent to manufacture of the base, wherein the contact members are positioned within selected ones of the passages according to a desired operating configuration of the switch assembly; a combination lift and detent arrangement formed integrally with the base and the rotary contact arrangement for lifting the rotary contact area of the rotary contact arrangement away from the stationary contact areas of the base upon rotation of the rotary contact arrangement between the stationary contact areas, and for releasably maintaining the rotary contact arrangement in a selected one of the contact positions; a center contact engaged with the base and defining a stationary center contact area, wherein the rotary contact arrangement includes a rotary inner contact area engageable with the stationary center contact area upon rotation of the rotary contact arrangement, wherein the center contact and the base include cooperating engagement structure for engaging the center contact with the base subsequent to manufacture of the base; wherein the rotary contact arrangement includes an actuator shaft rotatably mounted to the base, wherein the actuator shaft includes a forward section located forwardly of the base and a rearward section located rearwardly of the base, wherein the forward section of the actuator shaft mounts an actuator handle which is manually engageable by a user for imparting rotation to the rotary contact arrangement; wherein at least a second rotary indexing switch assembly is mounted rearwardly of the base, wherein the first and second rotary indexing switch assemblies include respective first and second actuator shafts, wherein the forward section of the second actuator shaft and the rearward section of the first actuator shaft include mating engagement structure for imparting rotation to the second actuator shaft upon rotation of the first actuator shaft; a conical spring interposed between the actuator shaft and the rotary contact arrangement for biasing the rotary contact areas toward the radially spaced stationary contact areas of the base; an enclosure wall formed integrally with the base, wherein the radially spaced stationary contact areas are located in a contact surface defined by the base, and wherein the enclosure wall and the contact surface cooperate to define an internal cavity within the stationary contact areas and the rotary contact area are located.
  • 2. A rotary indexing switch assembly, comprising:a base defining a plurality of stationary contact areas; a rotary contact arrangement mounted for rotary movement relative to the base, wherein the rotary contact arrangement includes at least one rotary contact area, wherein the rotary contact arrangement is movable to a plurality of contact positions in which the at least one rotary contact area of the rotary contact arrangement engages at least one of the plurality of stationary contact areas of the base; an insulating member separate from the base and mounted to the base, wherein the insulating member includes a series of radially spaced passages; and a plurality of contact members engaged within the series of radially spaced passages of the insulating member, wherein each of the radially spaced passages in the insulating member receives one of the contact members, wherein the plurality of contact members define the plurality of contact areas, and wherein the contact members are positioned within selected ones of the passages in the insulating member according to a desired operating configuration of the switch assembly.
  • 3. The rotary indexing switch assembly of claim 2, wherein at least a first one of the contact members is inserted into a first one of the passages in the base, and wherein the first passage in the base includes a transverse wall that is pierced by the first contact member as the first contact member is inserted into the first passage.
  • 4. The rotary indexing switch assembly of claim 2, wherein the rotary contact arrangement comprises an actuator shaft rotatably mounted to the base, and a rotary contact member engaged with the actuator shaft and rotatable therewith, wherein the rotary contact member includes at least one rotary contact area engageable with the stationary contact areas defined by the contact members.
  • 5. A rotary indexing switch assembly, comprising:a base having a series of radially spaced stationary contact areas; a rotary contact arrangement mounted for rotary movement relative to the base, wherein the rotary contact arrangement includes at least one rotary contact area, wherein the rotary contact arrangement is movable to a plurality of contact positions in which the at least one rotary contact area of the rotary contact arrangement engages at least one of the stationary contact areas of the base; wherein the base includes a series of radially spaced passages, and wherein the stationary contact areas are defined by a plurality of contact members, wherein each of the contact members is received within one of the passages in the base subsequent to manufacture of the base, wherein the contact members are positioned within selected ones of the passages according to a desired operating configuration of the switch assembly; and a center contact engaged with the base subsequent to manufacture of the base.
  • 6. A rotary indexing switch assembly, comprising:a base having a series of radially spaced stationary contact areas; a rotary contact arrangement mounted for rotary movement relative to the base, wherein the rotary contact arrangement includes a rotary contact area, wherein the rotary contact arrangement is movable to a plurality of contact positions in which the rotary contact area of the rotary contact arrangement engages at least one of the series of stationary contact areas of the base; and a combination lift and detent arrangement formed integrally with the base and the rotary contact arrangement for lifting the rotary contact area of the rotary contact arrangement away from the stationary contact areas of the base upon rotation of the rotary contact arrangement between the stationary contact areas, and for releasably maintaining the rotary contact arrangement in a selected one of the contact positions.
  • 7. The rotary indexing switch assembly of claim 6, wherein the combination lift and detent arrangement includes ramp structure formed on the base and at least one lift member associated with the rotary contact arrangement, wherein the at least one lift member engages the ramp structure upon rotation of the rotary contact arrangement to lift the at least one rotary contact area away from the base.
  • 8. The rotary indexing switch assembly of claim 7, wherein the ramp structure comprises a series of individual radially spaced ramps formed integrally with the base, wherein each of the series of ramps is located so as to correspond in location to one of the series of stationary contact areas.
  • 9. The rotary indexing switch assembly of claim 8, wherein the at least one lift member comprises a pair of spaced apart lift members, wherein the rotary contact area is located between the pair of lift members, wherein, when the rotary contact area is in engagement with an engaged one of the stationary contact areas of the base, one of the series of ramps corresponding to the engaged stationary contact area is received between the pair of lift members.
  • 10. The rotary indexing switch assembly of claim 8, wherein the rotary contact arrangement includes a pair of spaced apart rotary contact areas, and wherein the at least one lift member is located between the pair of spaced apart rotary contact areas, wherein, when the spaced apart rotary contact areas are engaged with the first and second of the stationary contact areas of the base, the lift member is engaged with the ramps corresponding to the first and second of the stationary contact areas so as to maintain the spaced apart rotary contact areas in engagement with the first and second of the stationary contact areas.
  • 11. A rotary indexing switch assembly, comprising:a base having a series of radially spaced stationary contact areas; a rotary contact arrangement mounted for rotary movement relative to the base, wherein the rotary contact arrangement includes at least one rotary contact area, wherein the rotary contact arrangement is movable to a plurality of contact positions in which the at least one rotary contact area of the rotary contact arrangement engages at least one of the stationary contact areas of the base; and a center contact engaged with the base and defining a stationary center contact area, wherein the at least one rotary contact area of the rotary contact arrangement includes a rotary inner contact area engageable with the stationary center contact area upon rotation of the rotary contact arrangement, wherein the center contact and the base include cooperating engagement structure for engaging the center contact with the base subsequent to manufacture of the base.
  • 12. The rotary indexing switch assembly of claim 11, wherein the rotary contact arrangement includes an actuator shaft rotatably mounted to the base, and wherein the center contact includes an opening through which the actuator shaft extends.
  • 13. The rotary indexing switch assembly of claim 12, wherein the cooperating engagement structure comprises a cooperating engagement arrangement located on one side of the opening, and a fastener engaged between the center contact and the base on the opposite side of the opening.
  • 14. The rotary indexing switch assembly of claim 13, wherein the cooperating engagement arrangement comprises a tab formed on the center contact and a recess formed in the base within which the tab is received for engaging the center contact with the base on one side of the opening.
  • 15. The rotary indexing switch assembly of claim 14, wherein the center contact includes a mounting extension opposite the tab, wherein the fastener is engaged with the mounting extension and is received within an opening formed in the base.
  • 16. A rotary indexing switch assembly, comprising:a base having a series of radially spaced stationary contact areas; a rotary contact arrangement mounted for rotary movement relative to the base, wherein the rotary contact arrangement includes at least one rotary contact area, wherein the rotary contact arrangement is movable to a plurality of contact positions in which the at least one rotary contact area of the rotary contact arrangement engages at least one of the stationary contact areas of the base; wherein the rotary contact arrangement includes an actuator shaft rotatably mounted to the base, wherein the actuator shaft includes a forward section located forwardly of the base and a rearward section located rearwardly of the base, wherein the forward section of the actuator shaft mounts an actuator handle which is manually engageable by a user for imparting rotation to the rotary contact arrangement; and wherein a second rotary indexing switch assembly is mounted rearwardly of the base, wherein the first and second rotary indexing switch assemblies include respective first and second actuator shafts, wherein the forward section of the second actuator shaft and the rearward section of the first actuator shaft include mating engagement structure for imparting rotation to the second actuator shaft upon rotation of the first actuator shaft.
  • 17. The rotary indexing switch assembly of claim 16, wherein the mating engagement structure comprises radially spaced axially extending splines associated with the rearward section of the first actuator shaft and the forward section of the second actuator shaft.
  • 18. The rotary indexing switch assembly of claim 17, wherein the rearward section of the first actuator shaft defines a splined passage and wherein the forward section of the second actuator shaft is received within the passage and defines external splines engageable with the splines of the passage.
  • 19. The rotary indexing switch assembly of claim 16, further comprising positioning means for engaging the forward section of the second actuator shaft with the rearward section of the first actuator shaft in a predetermined position for attaining a predetermined alignment of the rotary contact arrangements of the first and second rotary indexing switch assemblies.
  • 20. The rotary indexing switch assembly of claim 19, wherein the mating engagement arrangement comprises a series of radially spaced axially extending splines associated with the forward section of the second actuator shaft and the rearward section of the first actuator shaft, and wherein the positioning means comprises a mating irregularity formed in the splines.
  • 21. The rotary indexing switch assembly of claim 16, further comprising a series of mounting members provided on the base of each of the first and second rotary switch assemblies, wherein the mounting members include an axially extending passage and wherein the second switch assembly is engaged with the first switch assembly via a fastener extending through the passage of each of the series of mounting members of the first switch assembly into engagement with the passage of each of the series of mounting members of the second switch assembly.
  • 22. A rotary indexing switch assembly, comprising:a base having a series of radially spaced stationary contact areas; a rotary contact arrangement mounted for rotary movement relative to the base, wherein the rotary contact arrangement includes at least one rotary contact area, wherein the rotary contact arrangement is movable to a plurality of contact positions in which the at least one rotary contact area of the rotary contact arrangement engages at least one of the stationary contact areas of the base, wherein the rotary contact arrangement includes an actuator shaft and a rotary contact member engaged with the actuator shaft and including the at least one rotary contact area; and a conical spring interposed between the actuator shaft and the rotary contact member for biasing the rotary contact member toward the radially spaced stationary contact areas of the base.
  • 23. The rotary indexing switch assembly of claim 22, wherein the conical spring defines a passage through which the actuator shaft extends, and includes a first end spaced from the contact member and a second end in engagement with the contact member, wherein the second end has a transverse dimension greater than the first end.
  • 24. The rotary indexing switch assembly of claim 23, further comprising a spring retaining member engaged with the actuator shaft and with the first end of the conical spring, wherein the spring retaining member is positioned so as to compress the conical spring to bias the rotary contact member toward the stationary contact areas of the base.
  • 25. The rotary indexing switch assembly of claim 24, wherein the spring retaining member comprises a snap ring engaged within a groove defined by the actuator shaft.
  • 26. A rotary indexing switch assembly, comprising:a base having a series of radially spaced stationary contact areas; a rotary contact arrangement mounted for rotary movement relative to the base, wherein the rotary contact arrangement includes at least one rotary contact area, wherein the rotary contact arrangement is movable to a plurality of contact positions in which the at least one rotary contact area of the rotary contact arrangement engages at least one of the stationary contact areas of the base; and an enclosure wall formed integrally with the base; wherein the radially spaced stationary contact areas are located in a contact surface defined by the base, wherein the enclosure wall and the contact surface cooperate to define an internal cavity within which the stationary contact areas and the at least one rotary contact area are located.
  • 27. The rotary indexing switch assembly of claim 26, wherein the enclosure wall defines an end spaced from the contact surface, wherein the rotary indexing switch assembly is mounted to a member and wherein the end of the enclosure wall is engageable with the member to enclose the internal cavity defined by the enclosure wall and the contact surface.
  • 28. The rotary indexing switch assembly of claim 27, further comprising mounting structure associated with the base for use in mounting the rotary indexing switch assembly to the member.
  • 29. The rotary indexing switch assembly of claim 28, wherein the mounting structure comprises a plurality of mounting bosses, wherein each of the plurality of mounting bosses includes an axial passage that receives a fastener extending through the member for engaging the switch assembly with the member.
  • 30. The rotary indexing switch assembly of claim 29, wherein each mounting boss is located exteriorly of the internal cavity defined by the enclosure wall and the contact surface.
  • 31. The rotary indexing switch assembly of claim 27, wherein the rotary contact arrangement includes an actuator shaft rotatably mounted to the base and a rotary contact member engaged with and movable with the actuator shaft, wherein the rotary contact member includes the at least one rotary contact area, and farther comprising a biasing arrangement interposed between the actuator shaft and the rotary contact member for biasing the rotary contact member toward the contact surface, wherein the rotary contact member and the biasing arrangement are located within the internal cavity defined by the contact surface and the enclosure wall.
  • 32. A rotary indexing switch assembly, comprising:a base having a series of radially spaced stationary contact areas; a rotary contact arrangement mounted for rotary movement relative to the base, wherein the rotary contact arrangement includes at least one rotary contact area, wherein the rotary contact arrangement is movable to a plurality of contact positions in which the at least one rotary contact area of the rotary contact arrangement engages at least one of the stationary contact areas of the base; and a selectively positionable stop arrangement interposed between the rotary contact arrangement and the base for controlling the range of rotary movement of the rotary contact arrangement relative to the base.
  • 33. The rotary indexing switch assembly of claim 32, wherein the base includes a forward area and a rearward area, wherein the forward area contains the radially spaced stationary contact areas and wherein the rearward area contains the selectively positionable stop arrangement.
  • 34. The rotary indexing switch assembly of claim 33, wherein the rotary contact arrangement includes an actuator shaft rotatably engaged with the base, and wherein the actuator shaft is engageable with the stop arrangement for controlling the range of rotary movement of the actuator shaft, and thereby the rotary contact arrangement, relative to the base.
  • 35. The rotary indexing switch assembly of claim 34, wherein the actuator shaft includes a head portion located adjacent a surface defined by the rearward area of the base, wherein the head portion includes an outwardly extending engagement member, and wherein the stop arrangement includes at least one stop member extending from a surface defined by the rearward area of the base, wherein the engagement member is engageable with the stop member for controlling the range of movement of the actuator shaft relative to the base.
  • 36. The rotary indexing switch assembly of claim 34, wherein the stop arrangement comprises a pair of stop members selectively engageable with the rearward area of the base.
  • 37. The rotary indexing switch assembly of claim 36, wherein the rearward area of the base defines a surface having a series of radially spaced apertures, wherein the pair of stop members are selectively engageable within a selected pair of the apertures, wherein the stop members are positioned within a selected pair of the apertures which correspond to the range of rotary movement of the rotary contact arrangement relative to the base.
  • 38. A method of producing a rotary indexing switch assembly, comprising the steps of:providing a base having a series of radially spaced stationary contact areas; providing an actuator shaft; providing a first rotary contact member having a first contact area constructed and arranged to engage the series of stationary contact areas in a first configuration; providing a second rotary contact member having at least one second rotary contact area constructed and arranged to engage the series of stationary contact areas in a second configuration; and securing either the first rotary contact member or the second rotary contact member to the shaft and rotatably securing the shaft to the base, for providing either a first switch assembly capable of engaging the series of stationary contact areas in the first configuration or a second switch assembly capable of engaging the series of stationary contact areas in the second configuration.
  • 39. The method of claim 38, wherein the step of securing the actuator shaft to the rotary contact member is carried out by passing the actuator shaft through an opening in the selected rotary actuator member and inserting the actuator shaft through a passage in the base.
  • 40. A method of producing a base for a rotary switch assembly having a rotary contact member rotatably mounted to the base, comprising the steps of:forming the base with a base surface, wherein the base surface faces in a first direction and wherein the rotary contact member is adapted to be placed adjacent the base surface; and selectively engaging a plurality of contact members with the base after the base is formed, wherein each of the plurality of contact members has a contact surface facing generally in the first direction and configured for engagement with the rotary contact member, wherein the step of engaging the plurality of contact members with the base is carried out by forming a plurality of passages in an insulating ring and selectively engaging the plurality of contact members within selected ones of the plurality of passages in the insulting ring, and engaging the insulating ring with the base.
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