Introduction
Main causes of Micro switch failure
The most common failure mode is mechanical wear and fatigue. The spring blades inside the Micro switch undergo changes in stroke and elasticity after numerous cycles of operation, eventually resulting in poor contact or inability to reset. When the switch is connected to circuits with inductive or capacitive loads, arcs will be generated. The high temperature of the arcs will oxidize, corrode, or burn the surface materials of the contacts, increasing the contact resistance and even causing the contacts to fail to adhere. Dust, oil, and other substances entering the switch can also cause contact failures. Moisture, extreme high or low temperatures, or chemical reagents can cause certain damage to the internal materials of the switch. Overload and impact currents, as well as improper installation and operation, are also two major causes of Micro switch failure.
How to improve the reliability of Micro switches
"The failure of Micro switches is often the result of the combination of mechanical, environmental, and electrical factors. Optimization in a single aspect is difficult to solve the problem completely." A senior engineer in the field of Micro switches pointed out, "We adhere to the 'full-chain prevention' concept: from strict testing of each batch of materials, to the micrometer-level precision control in automated production, to 100% electrical performance inspection before leaving the factory, every step aims to minimize the failure rate and lay a solid foundation for the reliable operation of downstream equipment."
To address the problems causing the failure of Micro switches mentioned above, the industry has formed a systematic solution through material upgrades, structural optimization, and process innovation. High-performance spring blade materials are adopted, and the products need to undergo millions or even tens of millions of cycle tests to ensure long-term stability and resistance to mechanical wear. Materials such as silver alloy and gold plating are used to enhance the conductivity and anti-arc corrosion of the contacts, protecting the contacts from damage. Heat-resistant plastics are selected to ensure normal operation in harsh environments. At the same time, the products clearly indicate electrical and mechanical lifetimes and provide load reduction curves to assist in precise selection.
Post time: Sep-10-2025
