Limit Switch

One type of limit switch you might be familiar with is similar to a standard
light switch (known as a maintained limit switch). It remains in the on or off
position until force is applied. Limit switches are used to turn on or off a
device when triggered by the targeted object when it comes into contact
with the actuator. The actuator is the automated portion of the limit switch
(vs. the manual portion of a light switch) that sets the mechanism into
motion.
As its name suggests, a limit switch regulates the operations of machines
that are equipped with moving parts connected to a switching action
mechanism. A wide range of industrial machinery uses limit switches to
control the movement of devices performing on a production line, but these
switches are also found in non-industrial applications, such as electric motor
operation and garage door opener units. In the case of a garage door opener,
a limit switch is responsible for turning off the motor that lifts the door before
the door crashes into the lifting mechanism. The switch also deactivates the
motor as the door closes, preventing it from being pushed into the ground.
Limit switches enable this and similar operations to work as semiautomatic
processes by regulating an initiated action to keep it within performance
parameters.

When installed in a machine system, a limit switch can usually start, stop,
slow down, or accelerate operations, as well as activate a forward or reverse
process. In order to perform these actions, limit switches are designed in a
variety of shapes, sizes, and capacity ranges to accommodate differences in
machine systems and production processes. A limit switch is typically
composed of a series of electrical contacts coupled to an actuator that
controls the mechanical device responsible for on and off functions. Limit
switch instruments are employed in a broad range of applications due to
their straightforward design, relatively simple installation requirements,
reliability, and resilience in withstanding environmental conditions.

Types of Limit Switches

Limit switch performance depends on a number of factors. In addition to the

operational parameters and mechanical specifications of a machine, these
factors include the size, mounting method,
and force capacity of the switch, as well as
the stroke rate involved in the operating
process. It is important for a limit switch’s
electrical rating to match that of the system
into which it is installed in order to reduce
the potential for instrument failure and
ensure proper functioning. The common types of limit switches used in
industrial applications include:

• Heavy-Duty Precision Oil-Tight: Also known as the Type C limit switch,

this device is highly reliable due to its long electrical and mechanical
lifespan. It features a straightforward wiring arrangement and relatively easy
installation. The Type C can be equipped with a range of different head and
body styles, including a more durable design that is watertight and
submersible. It is available in a standard format, as well as with specialized
reed contacts.

• Heavy-Duty Oil-Tight and Foundry: When load requirements exceed

the capacity range for a precision oil-tight switch, a regular heavy-duty oil-
tight model, or Type T, may be needed. It can handle operating sequences
unavailable on the Type C and can withstand high trip and reset forces. The
heavy-duty foundry limit switch, or Type FT, is commonly used in foundries
and mills where Type T operating conditions are coupled with elevated
temperatures and foreign materials that may jam other types of switches.

• Miniature Enclosed Reed: This limit switch, also known as Type XA, is a
smaller and less expensive device formed from die-cast zinc. It contains a
contact array featuring a hermetically sealed reed, which makes it well-
suited for applications that require a high level of contact reliability or
involve environmental stresses. The switch is normally prewired and can be
placed in smaller or harder to reach areas.

• Gravity Return: The gravity return limit switch is usually employed in

production line and conveyor operations involving small, lightweight
components. This type of switch relies on gravity to reset its contact
switches by exerting force on a lever arm and typically functions with a low
level of torque. There are several varieties of gravity return switches,
including spring return, roller type, lever type, top push, and maintained
contact designs.

• Snap Switches: A snap switch is designed to instantly trigger as soon as

the mechanism attached to the switch has moved a predetermined distance,
regardless of the speed at which the moving part travels. Snap switches are
commonly used in applications that require only basic contact parameters
and can work with or without an operator. They are effective in machine
systems that feature short movements or a slow rate of operation.

Limit Switch Circuitry

To better understand the way a limit switch circuit operates, it may help to
look at an example that illustrates contact switching principles. A limit switch
with a single-station, maintained contact design will have a “Start” button
that mechanically controls the contacts. Pressing the “Start” button causes
the mechanism to maintain the contact sequence that closes the circuit,
while pressing the “Stop” button will open the contacts and break the circuit.
If a system malfunction, such as power failure or overloading, causes the
switch device to deactivate, the contacts will be unaffected and the motor
will automatically reset.