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3D printed Heavy Duty commutator

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  • 3D printed Heavy Duty commutator

    These days are good only to sit and work.
    I've been manufacturing remote controls for tractor winches for few years now.
    I made several models, depending on customer demands.
    Radio communication is encoded and secure, flawless so far.
    Range is 300 meters (customer demand) although it can go up to 1.8km with the same radio chips.
    Only problem that i got so far is the quality of "buttons" (switches).
    They don't last long, usually after 2-3 months they stop functioning properly.
    No matter the quality, those will fail after a while. For simple reason; those are usually pressed hard several hundreds time per day.
    That's simply the nature of such job.
    So i tried so many brands and models so far. Some are lasting bit more. But none survived at least one season of lumber jacking.
    So i came up with different solution. Micro switches with lever and 3 poles. Very durable.
    Even that is not enough, so i put 2 of those per one button. If somehow one fails; second one will not.
    Also the "mechanics" is done such way to prevent any uncontrolled hard pressing. Pressing is "soften" and amortized by the mechanical limitations.
    There is almost none resistance to the press. But one can not hard press the button and apply any redundant force on it.
    This should be now "eternal" commutator for the remote control.
    First i made one larger, bulky. Than i refined it and made it more compact (last photo).


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    3D printing is a mighty stuff! Can solve many problems.
    Electronic is based on Atmega and mighty yet low consuming radio chip.
    Receiver is equipped with 30Amps H-bridge mosfets.
    This thing is already proven on the field.
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