How do I improve switch reliability?

Switch selection is an important aspect of any new or existing design.  Ensuring applications have a switch that is reliable, durable and able to meet the demands of the product and end-user is essential.  So, what factors do you need to consider when improving switch reliability?

• Using a higher rated switch than the application requires helps to protect the switch from overloading. This is especially important for inductive loads like motors, solenoids and transformers.
• In some applications, the startup current can be several times higher than the current used during the normal running state. Controlling the inrush current by using a relay, soft-start circuit or inrush limiter can help protect the switch from an initial overload.
• Protect against arcing – switching inductive loads can create voltage spikes. Voltage spikes can lead to sparking which may cause switch contacts to weld together.  Ensure the switches maximum voltage and current are not exceeded.
• Keep contacts clean and dry — contamination, oxidation, moisture, and dust increase contact resistance and intermittent failures.
• Mechanical overstress such as vibration, excessive force and repeated operation beyond the switches cycle life can lead to failures. Try to avoid mechanical overstress.
• Test under real conditions — measure voltage/current during switching and inspect failures to determine whether the dominant problem is arcing, overheating, mechanical wear, corrosion, or electrical noise.

Need advice on switch reliability?

We have been supplying switches to OEMs and subcontractors within a wide range of industries for 40 years. Whether you are developing a new product or experiencing reliability issues with an existing switch application, our team can help you identify the right solution.

Call us on 01258 456360 or email sales@abcomponents.co.uk to discuss your application. We’ll be happy to help.