The present disclosure relates to a switch assembly for a vehicle. More specifically, the present disclosure relates to a lever combination switch provided with steering angle sensor for a steering wheel.
BACKGROUND OF THE DISCLOSURE
The existing vehicles have a lever combination switch installed around the shaft of a steering wheel. The lever combination switch is provided with operation levers for operating a wiper unit or a turn signal unit or lights of the vehicle. Further, the existing vehicles are provided with a steering angle sensor for detecting the direction and angle of rotation of the steering wheel. These lever combination switch and the steering angle sensor of the existing vehicle are mounted as two separate assemblies. Further, the SAS cover and different PCB assemblies were integrated to the switch assembly as they were separate units.
The main problem with the existing lever combination switch and steering angle sensors is that it requires more assembly time as lever combination switch is assembled on a separate line and steering angle sensor is assembled on a separate line and finally both assembled to make final assembly of lever combination switch with steering angle sensor. Yet another problem is the presence of more number of parts in existing assemblies, the cost of manufacturing is more. Moreover, to maintain and control the dimensions of all the parts is very difficult.
In the conventional lever combination switch assemblies, there was a difficulty in integration of PCB assemblies as there was height difference between the steering rod connector and steering of the vehicle. Further, the SAS cover was a separate unit and then integrated in the lever combination assemblies conventionally.
Therefore, to overcome the above problems, a switch assembly is disclosed which addresses one or more problems associated with the existing switches.

SUMMARY OF THE DISCLOSURE
One or more shortcomings of conventional assemblies are overcome, and additional advantages are provided through the provision of a lever combination switch assembly as defined in the present disclosure.
Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the present disclosure.
A lever combination switch assembly is disclosed. The lever combination switch assembly comprises a top cover and a bottom cover forming an encapsulation and having a co-axial through hole to dispose a steering column. The bottom cover accommodating a PCB sub assembly comprising of a print circuit board is accommodated in a receptacle formed in the bottom cover. A driving gear having a plurality of teeth and a plurality of pinions are rotatably disposed over the top cover such that a shaft portion of the pinions are exposed over the printed circuit board. A SAS cover is employed to cover the driving gear and the plurality of pinions. A magnet is disposed on each of the shaft portion of the plurality of pinions.
In an embodiment of the present disclosure, the driving gear and the plurality of pinions are rotatably disposed over a plurality of recesses formed on the top cover.
In an embodiment of the present disclosure, the teeth of the driving gear are engaged with the teeth of the plurality of pinions such that the pinions function as driven gears.
In an embodiment of the present disclosure, the SAS cover has guiding bosses to rotatably dispose the driving gear and the plurality of pinions.
In an embodiment of the present disclosure, a guide rib is provided in the driving gear to constrain any relative motion of the driving gear with respect to a steering column.
In an embodiment of the present disclosure, the guide rib transmits the rotation of steering column without any loss of torque.
In an embodiment of the present disclosure, the SAS cover comprises a plurality of latching protrusions to snap lock with the top cover.

In an embodiment of the present disclosure, a mounting cap is mounted on the bottom cover.
A lever combination switch assembly is disclosed. The switch assembly comprises a top cover having a top end and a bottom end. A bottom cover forming an encapsulation with the top cover. A plurality of modules mounted below a top cover. A PCB sub assembly comprising of a print circuit board accommodated in the receptacle of the bottom cover and a plurality of magneto sensitive angle sensors. A driving gear and a plurality of pinions rotatably disposed over the top cover such that a shaft portion of the pinions are exposed outside the bottom end of the top cover. A magnet disposed on each of the shaft portion of the plurality of pinions. A SAS cover employed to cover the driving gear and the plurality of pinions; A guide rib is provided in the driving gear to constrain any relative motion of the driving gear (20) with respect to a steering column.
In an embodiment of the present disclosure, the driving gear and the plurality of pinions are rotatably disposed over plurality of recesses formed on the top cover.
In an embodiment of the present disclosure, the driving gear is mounted on the steering column such that the driving gear rotates with the rotation of the steering.
In an embodiment of the present disclosure, the SAS cover has guiding bosses to rotatably dispose the driving gear and the plurality of pinions.
In an embodiment of the present disclosure, the SAS cover comprises a plurality of latching protrusions to snap lock with the top cover.
In an embodiment, a top cover comprises a circular wall which avoids tilting of the plurality of pinions.
In an embodiment, locks are provided in the lever combination switch assembly housing and corresponding slots are provided in the SAS module housing to facilitate assembly of SAS module with the lever combination switch assembly housing

BRIEF DESCRIPTION OF FIGURES
The novel features and characteristics of the disclosure are set forth in the description. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:
Figure 1 illustrates an exploded view of the lever combination switch assembly according to the present disclosure.
Figure 2 illustrates a perspective view of the assembled lever combination switch assembly according to the present disclosure.
Figure 3 illustrates a perspective view of the lever combination switch assembly without the top cover and SAS cover according to the present disclosure.
Figure 4 illustrates an exploded view of the lever combination switch assembly according to another embodiment of the present disclosure.
Figure 5 illustrates a perspective view of the lever combination switch assembly shown in figure 4, without the bottom cover according to the present disclosure.
Figure 6 illustrates a perspective view of the lever combination switch assembly shown in figure 4 according to the present disclosure.
Figure 7 illustrates a sectional view depicting the guiding bosses of the SAS cover according to the present disclosure.
Figure 8 illustrates an alternate embodiment of the lever combination switch assembly according to the present disclosure.
Figure 9 illustrates an exploded view of the lever combination switch assembly according to alternate embodiment of the present disclosure.
Figure 10 illustrates a perspective view of the lever combination switch assembly
according to alternate embodiment of the present disclosure.
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Figure 11 illustrates a sectional view of the lever combination switch assembly according to alternate embodiment of the present disclosure.
Figure 12 illustrates another alternate embodiment of the lever combination switch assembly according to the present disclosure.
Figure 13 illustrates an exploded view of the lever combination switch assembly according to another alternate embodiment of the present disclosure.
Figure 14 illustrates a sectional view of the lever combination switch assembly according to another alternate embodiment of the present disclosure.
The accompanying drawings depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DESCRIPTION OF PRESENT DISCLOSURE
While the invention is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the figures and will be described in detail below. It should be understood, however that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the invention as defined by the appended claims.
Before describing in detail embodiments, it may be observed that the novelty and inventive step that are in accordance with the present invention resides in lever combination switch assembly for vehicles. It is to be noted that a person skilled in the art can be motivated from the present invention and modify the various constructions of assembly, which are varying from vehicle to vehicle. However, such modification should be construed within the scope and spirit of the invention. Accordingly, the drawings are showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the
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art having benefit of the description herein.
The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus proceeded by "comprises... a" does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
Embodiments of the present disclosure discloses a lever combination switch assembly. The lever combination switch assembly is mounted on the steering area of vehicles. The lever combination switch assembly eliminates the use of multiple PCB assemblies and includes a single PCB assembly for its working.
Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Where ever possible same numerals will be used to refer to the same or like parts.
The present disclosure provides a lever combination switch (interchangeably referred to as a switch assembly) with integrated steering angle sensor. Figure 1 and Figure 2 illustrates a lever combination switch (100) assembly for vehicle according to an embodiment of the present disclosure. The switch (100) assembly comprises of a SAS cover (10), a driving gear (20), a plurality of pinions (30), a top cover (40), a plurality of function modules such as a light function module (50), a wiper function module (60), a PCB sub assembly (70), a bottom cover (80), and a mounting cap (90).
A bottom cover (80) substantially comprises of a receptacle formed as a casing so that different function modules along with PCB assembly can be disposed in the bottom cover (80). According to an embodiment of the present disclosure, the light function module (50), wiper function module (60) and the PCB sub assembly (70) are disposed in to the bottom cover (80). A through hole (81) is formed in a centre of the bottom cover (80) to accommodate a steering column (not shown in Figures) of the vehicle. According to an embodiment of the present disclosure, the wiper function module (60) with a wiper operation lever (61) is installed at the left side of the bottom cover
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(80), and the light function module (50) with a turn signal operation lever (51) is installed at the right side of the bottom cover (80). It should be noted that, in the case of a left-hand drive vehicle, light function module (50) is disposed on the left side of the bottom cover (80) and the wiper function module (60) is disposed on the right side of the bottom cover (80).
In order to integrate a steering angle sensor in the present switch assembly, the PCB sub assembly (70) comprising of a printed circuit board (71) is accommodated in to the receptacle formed in the bottom cover (80), as shown in Figure 3. The PCB sub assembly also comprises of magneto-sensitive angle sensors (not shown in the Figures) to detect the steering angle rotations.
According to an embodiment of the present disclosure, the top cover (40) forms an encapsulation with the bottom cover (80) and functions as a housing for the elements inside the bottom cover (80). The top cover (40) has a through hole (41) formed in the centre of the top cover (40) to accommodate a steering column (not shown in Figures) of the vehicle. According to an embodiment of the present disclosure, for detecting the steering angle of the steering wheel, the driving gear (20) and a plurality of pinions (30) are rotatably disposed over the top cover (40) such that the shaft portion of the pinions (31) are exposed over the printed circuit board (71) present inside the bottom cover (80). The driving gear (20) and the plurality of pinions (30) are rotatably disposed over some recesses (not shown in the Figures) formed over the top cover (40). The driving gear (20) is mounted to the steering column of the steering wheel (not shown in the Figures), such that driving gear rotates with the rotation of the steering. The teeth of driving gear (20) are engaged with the teeth of the plurality of pinions (30), such that the pinions (30) functions as driven gears. A guide rib (21) is provided in the driving gear (20) to constrain any relative rotation of the driving gear (20) with respect to the steering column and also to transmit the rotation of steering column without any loss of torque.
According to an embodiment of the present disclosure, a SAS cover (10) is employed to cover the driving gear (20) and a plurality of pinions (30) are rotatably disposed over the top cover (40). The SAS cover has guiding bosses to rotatably dispose the driving gear (20) and a plurality of pinions (30). The SAS cover (10) and the top
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cover (40) has a through hole formed in the centre to accommodate a steering column (not shown in Figures) of the vehicle. The top cover (40) is mounted over the bottom cover (80) by fastening elements such as nuts (91). Whereas fastening elements such as screws (92) are utilised to mount the SAS cover (10) with the top cover (40). A mounting cap (90) is used to protect the exposed extremity of the through hole (81) formed in the centre of a bottom cover (80) from external influences such as dust.
In another embodiment of the present disclosure, as shown in Figure 4, which depicts an alternate method of arrangement of elements in the switch assembly (100) for a vehicle. Here, the light function module (50) and the wiper function module (60) is mounted below a top cover (45). Whereas, the driving gear (20) and a plurality of pinions (30) are rotatably disposed over the top cover (45) such that the shaft portion (31) of the pinions (30) are exposed outside the bottom of top cover (45). The top cover (45) has a through hole (46) formed in the centre to accommodate a steering column (not shown in Figures) of the vehicle. The driving gear (20) and the plurality of pinions (30) are rotatably disposed over some recesses (not shown in the Figures) formed over the top cover (45). The driving gear (20) is mounted to the steering column of the steering wheel (not shown in the Figures), such that driving gear rotates with the rotation of the steering. The teeth of driving gear (20) are engaged with the teeth of the plurality of pinions (30), such that the pinions (30) function as driven gears. According to an embodiment of the present disclosure, a guide rib (21) is provided in the driving gear (20) to constrain any relative rotation of the driving gear (20) with respect to the steering column and also to transmit the rotation of steering column without any loss of torque.
In order to integrate a steering angle sensor, the PCB sub assembly (70) comprising of a printed circuit board (71) is accommodated in to the receptacle of a bottom cover (85), as shown in Figure 4 and Figure 5. The PCB sub assembly also comprises of magneto-sensitive angle sensors (not shown in the Figures) to detect the steering angle rotations. The top cover (45) further comprises of a plurality of latch protrusions to secure the bottom cover (85) with the top cover (45). Whereas, the bottom cover (85) has a plurality of latching holes to snap lock the latching protrusions present on the top cover (45).
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According to an embodiment of the present disclosure, a SAS cover (15) is employed to cover the driving gear (20) and a plurality of pinions (30) are rotatably disposed over the top cover (45). The SAS cover has guiding bosses (16) to rotatably dispose the driving gear (20) and a plurality of pinions (30) as shown in Figure 7. The SAS cover (15) and the top cover (45) has a through hole formed in the centre to accommodate a steering column (not shown in the Figures) of the vehicle. A plurality of latching protrusions over SAS cover (15) are provided to snap lock and affix with the plurality of latching holes on the top cover (45).
According to an embodiment of the present disclosure, the working of the switch assembly is described as following, whenever the steering wheel rotated clockwise or anticlockwise by any predetermined angle, the guiding rib (21) which is linked to the steering column, rotates similar angle as that of steering wheel rotation angle. As a plurality of pinions (30) establishes a gear train with the driving gear (20) by a predetermine gear ratio, said plurality of pinions also rotates by the predetermined angle as per the gear ratio, clockwise or anticlockwise.
A magnet (not shown in the Figures) is disposed with in each of the shaft portion (31) of the plurality of pinions (30). The magnets have a predetermined magnetic flux density to the magneto-sensitive angle sensors (not shown in the figures) mounted just below to the each of the said magnet. Whenever the plurality of pinions (30) rotates with the rotation of the steering wheel, the magnets disposed within the shaft portion (31) of the plurality of pinions (30) creates a change in magnetic flux. The magneto-sensitive angle sensors present below the shaft portion (31) of the plurality of pinions (30) measures the change in magnetic flux and the value of angular rotation of steering wheel is determined and processed by a microcontroller (not shown in the figures) connected to the printed circuit board (71).
Referring to Figure 8 which is an alternate embodiment of the present disclosure, a SAS module comprising of gear train without PCB assembly is shown for functioning of the SAS module. Also, a single PCB assembly has been incorporated with the functions of the SAS module. The SAS mechanical module is designed to be fitted in other LCS with the features of the SAS module.
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Referring to Figures 9 and 10, an exploded view of the assembly according to an alternate embodiment of the present disclosure is shown. In this embodiment, a top cover comprises a circular wall which avoids tilting of the plurality of pinions as shown in Figure 10 during the clockwise and anti-clockwise axial rotation. This is achieved by required clearance provided between the housing wall and the pinion wall.
Referring to Figure 11, an alternate embodiment of the present assembly is shown. In this embodiment, locks are provided in the lever combination switch assembly housing and corresponding slots are provided in the SAS module housing to facilitate assembly of SAS module with the lever combination switch assembly housing. Referring to Detail A, a circular rib guiding a pinion is shown. This embodiment provides standardisation of a mechanical module for steering angle sensing by using it in multiple designs. The present embodiment reduces assembly time, tooling cost and manufacturing cost. The embodiment also eliminates use of separate PCB required for SAS by integrating SAS features in the single PCB assembly.
Referring to Figures 12-14 and Detail B, another alternate embodiment of the present disclosure is shown where the lever combination switch assembly integrated with the SAS features on single PCB assembly and SAS mechanical module is shown. In this embodiment, the magnetic sensors are provided for sensing variation in the magnetic flux density to measure the steering angle. In this embodiment, a single PCB assembly comprises of steering angle sensing features. Further, in this embodiment, a top cover comprises a circular wall which avoids tilting of the plurality of pinions as shown in Figure 14 during the clockwise and anti-clockwise axial rotation. This is achieved by required clearance provided between the housing wall and the pinion wall. The embodiment may comprise a wiper switch and a light switch.
According to an embodiment of the present disclosure, the primary advantage of the present switch assembly is to integrate the lever combination switch with features of steering angle sensor.
In an embodiment, the switch assembly is a cost-effective solution for manufacturing the components.
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In an embodiment, the switch assembly disclosed has minimum number of parts, and reduces assembly time.
In an embodiment, the switch assembly provides an effective seal and doesn't allow entry of foreign particles into the assembly.
Further, various modifications and variations may be made without departing from the scope of the present invention. Therefore, it is intended that the present disclosure covers such modifications and variations provided they come within the ambit of the appended claims and their equivalents
EQUIVALENTS;
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
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Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression "at least" or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles and the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
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LIST OF REFERENCE NUMERALS

Description Reference Number
Combination lever switch assembly 100
SAS cover 10
SAS cover according to another embodiment 15
Guided bosses of SAS cover 15 16
Driving gear 20
Guide rib 21
Plurality of pinions 30
Top cover 40
Top cover according to another embodiment 45
Through hole on top cover 40 41
Through hole on top cover 45 46
Wiper function module 60
Wiper operation lever 61
Light function module 50
Light operation lever 51
PCB sub assembly 70
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Printed circuit board 71
Bottom cover 80
Tlirough hole in the bottom cover 81
Bottom cover according to another embodiment 85
Mounting clamp 90
Nuts 91
Screws
Permanent magnet
Magnetic sensor 92
120
121

We Claim:

A lever combination switch assembly (100) comprising:
a top cover (40) and a bottom cover (80) forming an encapsulation and having a co-axial through hole (81) to dispose a steering column; the bottom cover accommodating:
a PCB sub assembly (70) comprising of a print circuit board accommodated in a receptacle formed in the bottom cover (80);
a driving gear (20) having a plurality of teeth and a plurality of pinions
(30) rotatably disposed over the top cover (40) such that a shaft portion
(31) of the pinions (30) are exposed over the printed circuit board;
a plurality of modules (50,60);
a magnet disposed on each of the shaft portion (31) of the plurality of pinions (30).
a SAS cover (10) employed to cover the driving gear (20) and the plurality of pinions (30).
2. The lever combination switch assembly (100) as claimed in claim 1, wherein the driving gear (20) and the plurality of pinions (30) are rotatably disposed over a plurality of recesses formed on the top cover (40).
3. The lever combination switch assembly (100) as claimed in claim 1, wherein the teeth of the driving gear (20) are engaged with the teeth of the plurality of pinions (30) such that the pinions function as driven gears.
4. The lever combination switch assembly (100) as claimed in claim 1, wherein the SAS cover (10) has guiding bosses to rotatably dispose the driving gear (20) and the plurality of pinions (30).
5. The lever combination switch assembly (100) as claimed in claim 1, wherein a guide rib (21) is provided in the driving gear (20) to constrain any relative motion of the driving gear (20) with respect to the steering column.

6. The lever combination switch assembly (100) as claimed in claim 5, wherein the guide rib (21) transmits the rotation of steering column without any loss of torque.
7. The lever combination switch assembly (100) as claimed in claim 1, wherein the SAS cover (10) comprises a plurality of latching protrusions to snap lock with the top cover.
8. The lever combination switch assembly (100) as claimed in claim 1, wherein a mounting cap (90) is mounted on the bottom cover (80).
9. A lever combination switch assembly (100) comprising:
a top cover (45) having a through hole (46) and top end and a bottom end;
a bottom cover (85) forming an encapsulation with the top cover;
a plurality of modules (50,60) mounted below a top cover (45);
a PCB sub assembly (70) comprising of a print circuit board (71) accommodated in the receptacle of the bottom cover (85) and a plurality of magneto sensitive angle sensors;
a driving gear (20) and a plurality of pinions (30) rotatably disposed over the top cover (45) such that a shaft portion of the pinions are exposed outside the bottom end of the top cover (45);
a magnet disposed on each of the shaft portion of the plurality of pinions (30);
a SAS cover (15) employed to cover the driving gear (20) and the plurality of pinions (30);
a guide rib (21) is provided in the driving gear to constrain any relative motion of the driving gear (20) with respect to a steering column.
10. The lever combination switch assembly (100) as claimed in claim 9, wherein the
driving gear (20) and the plurality of pinions (30) are rotatably disposed over plurality
of recesses formed on the top cover (45).

11. The lever combination switch assembly (100) as claimed in claim 9, wherein the driving gear (20) is mounted on the steering column such that the driving gear (20) rotates with the rotation of the steering.
12. The lever combination switch assembly (100) as claimed in claim 9, wherein the SAS cover (15) has guiding bosses (16) to rotatably dispose the driving gear (20) and the plurality of pinions (30).
13. The lever combination switch assembly (100) as claimed in claim 9, wherein the SAS cover (15) comprises a plurality of latching protrusions to snap lock with the top cover (45).
14. The lever combination switch (100) assembly as claimed in claim 1, wherein a top cover comprises a circular wall which avoids tilting of the plurality of pinions.
15. The lever combination switch assembly (100) as claimed in claim 1, wherein locks are provided in the lever combination switch assembly housing and corresponding slots are provided in the SAS module housing to facilitate assembly of SAS module with the lever combination switch assembly housing.