FORM 2
THE PATENT ACT 1970
&
The Patents Rules, 2003
PROVISIONAL / COMPLETE SPECIFICATION
(See section 10 and rule 13)

1. TITLE OF THE INVENTION
" AN INTEGRATED COMBINATION SWITCH"
2. APPLICANT
(a) NAME : SHUTHAM ELECTRIC LIMITED
(b) NATIONALITY : An Indian Company registered under the provisions of
The Companies Act, 1956.
(c) ADDRESS : Gat No. 819/1/2, Sanaswadi, Tal: Shirur
PUNE- 412 207, Maharashtra State, India
3. PREAMBLE TO THE DESCRIPTION
PROVISIONAL
The following specificajioffdescribes the
invention. COMPLETE
The following specification
particularly describes the invention and
the manner in which it is to be
performed.
4. DESCRIPTION (Description starts from page 2)
5. CLAIMS: Given on a separate page
6. DATE AND SIGNATURE: Given at the end of last page of specification.
7. ABSTRACT OF THE INVENTION: Given on a separate page
The following specification describes the nature of this invention.

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The present invention relates to an integrated combination switch
assembly. More particularly, it relates to an improved integrated combination
switch used in heavy commercial vehicles.
The present invention is used in heavy commercial vehicle to operate
headlight i.e. Dip or Dim, side indicator and horn wherein the headlights are
operated with respect to Dip or Dim. Thus, makes it a multi-utility single lever
switch.
The purpose of the invention is to provide an integrated single lever
operated multifunctional (combination switch) with various functions such as,
(a) Headlamps - High beam, low beam and flash beam by lever
movement in vertical direction.
(b) Direction indicator Left and Right with lane changing facilities along
with automatic self-cancellation feature by lever movement in
horizontal direction.
(c) Button Type horn switch at lever end for horn operation.
The object of the invention is to reduce the number of pivot joints to
actuate switch contact functions for various modes, hence consistency level in
sub-assemblies is better and accordingly, piece-to-piece variation is less. The
main aim of the invention is to make the mechanism precise and reliable.
Prior Art:
In the prior art, switch actuation is through lever along with various
numbers of pivoting joints.
a) Operating lever is assembled with snap box by pivot screw.
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b) For direction indicator switch, a spring box is operated through
actuating lever, which pivots in switch mounting plate.
c) Actuating lever gets actuated through switch lever.
d) In the Head / Dim Function switch, a spring box is pivoted inside
the switch. This spring has two spring's loaded steel balls, which
moves on the contact plate and is pivoted on terminals. This
movement of spring depends on snap box travel and snap box
gets operated through switch lever.
The prior art consists of rocker type mechanisms, which do not ensure
high current rating and moreover it needs to be essentially operated with relay.
In also consists of a horn mechanism wherein contact is assembled in
metallic plunger having groove and is locked with 'C' type lock. Since this is an
operator dependent, there are incidences where contact plate is dislodged
resulting in failure of the switch to perform its function.
The construction of the prior art is such that the contact terminal design is
hollow at the bottom. The cable and terminal is soldered on to the terminal and
the terminal is press fitted with base. The self-cancellation mechanism requires
additional parts making it less precise and less reliable.
Deficiencies in Prior Art:
1. It involves lots of pivot joints and therefore chances of pivot joints
getting break is frequent.
2. The moving contacts fall off and therefore result in failure of the
switch.
3. The mechanism used is less efficient, less precise and less reliable.
4. To obtain high current rating, it needs to be essentially operated
with relay.
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Present invention:
With a view to overcome the deficiencies found in the prior art the present
invention is introduced. According to present invention an integrated combination
switch assembly used in heavy commercial vehicle to operate headlight i.e. Dip
or Dim, side indicator and horn wherein the headlights are operated with respect
to Dip or Dim. Thus, makes it a multi-utility single lever switch.
The present invention provides an integrated single lever operated switch
having multiple functions in its mechanism. It its mechanism, high/low/flash beam
is operated by vertical movement of lever. It facilitates an indicator for showing
(Left and Right) direction. It also provides for changing lanes and self-
cancellation by horizontal movement of the lever. In addition, a button type horn
switch at lever end for horn operation is located to form a complete switch.
The present invention reduces the number of pivot joints to actuate switch
contact functions for various modes, hence consistency level in sub-assemblies
is better and accordingly, piece-to-piece variation is less. The mechanism of the
invention is precise and reliable as the sliding contacts do not fall and
accordingly, chances of its failure is less. Also, more current rating can be
operated without relay and therefore makes it more efficient and multi-utility.
Therefore according to this invention an integrated combination switch
assembly for use in heavy commercial vehicle comprises of switch-actuating
lever, which is assembled to a rotor by a metallic horizontal pivot pin through
riveting process; it also consists of action plunger along with spring to get
head/dim operation/snap feel of switch; the roller and roller carrier along with
spring are assembled on to the top of rotor; also an action plunger is assembled
with spring to get engagement action for direction indicator as well as self-
cancellation mechanism when it is pushed by striker bush through trigger / pawl
and is further fitted on to the switch cover; the Contact Pin is assembled with
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lighting fret in an automatic orbital riveting machine to assemble with contact pin
and is riveted into base; lighting contact plate along with spring shall be
assembled in contact slides in two places and is fit to the base slot and is
operated through the front portion of lever; a push actuator horn push button is
assembled at the end of the lever and accordingly final assembly of the unit is
made with two screws from bottom, which is locked by a metallic pivot pin i.e.
cover sub-assembly, base sub-assembly and lever sub-assembly and are riveted
from bottom to complete the entire assembly, which is then housed in an
enclosure to form a combination switch.
The invention is now described with the help of accompanying drawing.
Fig.1, Fig. 2, Fig 3(a), Fig 3(b), Fig 4, Fig. 5 (a), 5(b), 5 (c) and Fig. 6 shows
the entire construction of the system.
The switch mechanism consists of foflowing components:
1 Pivot Pin 2 Trigger 2A Trigger/Pawl
3 Rotor 4 Switch Cover 4A Housing
5 Lever 5A upward movement
of lever
6 Headlamp switch 6A Lighting fret
7 Contact Slide 8 Contact Pin 9 Base
10 Pivot Pin 11 Roller 11A Terminal
12 Action Slide 12A Terminal 13 Action
Plunger
13A Terminal 14 Spring (for left turn) 15 Roller Carrier
16 Horn Push Button 17 Action Plunger 18 spring
19 Spring (right turn) 20 Contact Pin 21 spring
22 Carrier 22A Contact carrier 22B Contact
Carrier
23 Lighting Contact 24 spring 25 Enclosure
Plate
26 Screw
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As shown in Fig. 1, the invention comprises of a switch-actuating lever
(5A/5), which is assembled with a rotor (3) by a metallic horizontal pivot pin (10)
through riveting process. The assembly also consists of action plunger (17) along
with spring (18) to get head/dim operation/snap feel of switch shown in Fig. 4,
In Fig.2, the roller (11) and roller carrier (15) along with spring (14) are
assembled on to the top of rotor. Action plunger (13) is assembled with spring
(19) to get engagement action for direction indicator as well as self-cancellation
mechanism when pushed by striker bush through Trigger / Pawl (2) in Fig. 1.
This assembly is fitted on to switch cover (4) in Fig, 1.
Fig. 5(c) shows that the Contact Pin (20) shall be assembled with lighting
fret (6A) in an automatic orbital riveting machine. This fitment of contact pin with
lightning fret is more clearly shown in Fig. 5(b). Lighting fret duly assembled with
contact pin shall be riveted into base (9A) shown in Fig. 5(c).
•Contact Pin (8) for direction indicator born link shall be assembled with
base (9) by riveting as shown in Fig.1. Lighting contact plate (23) along with
springs (24) shall be assembled in contact slide (22A) and (22B) in two places as
shown in Fig. 5 (a). This contact slide assembly is fit to the base slot, which is to
be operated through the front portion of lever (5) in Fig. 1. At the end of lever, a
push actuator horn push button(16) will be assembled at the end of the lever as
shown in Fig. 1.
Final assembly of the unit shall be made with two screws (26) from bottom as
shown in Fig, 2
A metallic pivot pin (1) is used to lock whole assembly i.e. cover sub-
assembly, base sub-assembly and lever sub-assembly and getting riveted from
bottom as shown in Fig. 1.
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This entire assembly shall be housed in an enclosure (25) as shown in Fig. 6.
Working of the invention:
The working of the invention is now described with the help, of
accompanying drawings. Fig.2 is a plan view of sub-assembly of switch cover,
rotor, lever, roller, carrier, actuator slider and pawl and action plunger. Fig.3 (a) is
a plan view to clearly show the position of action slide and cancellation pawl
whereas Fig. 3(b) is a side view of sub-assembly of switch cover, pawl, action
slide and spring. Fig. 4 is a side view of sub-assembly of lever, rotor,,snap
spring, snap plunger and horizontal pivot pin. Fig. 5(a), 5(b) and 5(c) is a plan
view and side view of sub-assembly of lighting contact, terminals, base, contact
slide, contact and spring. Fig. 6 is a final assembly of actuating group
subassemblies, which is enclosed in an enclosure.
Fig.2 is a plan view of sub-assembly of switch cover, rotor, lever, roller,
carrier, actuator slider and pawl and action plunger. The movement of lever (5) in
clockwise direction depresses roller (11) against the spring (14) for left turn and
(19) for right turn, which are housed in plunger (15). All these components are
held in a rotor (3) as shown in Fig. 4 on the can giving the first detent indicating
the lane change operation for right turn. This move enables the electric
connection for right turn indicator by connecting terminal 11(A) to terminal 13(A)
in Fig. 2. Further movement of lever in clockwise direction locks the detent in the
cam provided in the housing (4a). Similarly, anti clockwise movements connects
terminal 11(A) to terminal 12 (A) for the left turn indication. This action duly
detent is assisted by the action plunger (13), An assembly fixing screw (26) is
used to assemble the complete switch.
Fig.3 (a) is a plan view to clearly shows the position of action slide and
cancellation pawl. The movement of the lever in the clockwise direction shifts the
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action slide (12). When the driver is taking right turn, the cancellation trigger
keeps actuating cancellation pawl (2A) and it escapes without causing any
action. When the driver starts rotating the steering wheel in an anti clockwise
direction to make the wheels straight, the pawl actuates the projection, which is a
part of action slide (12) and pushes action slide back to the center. This brings
the lever back to center and accordingly self-cancellation is achieved. Similarly,
in case of left turn, the operation depends on spring (21), which makes the
cancellation pawl (2A) move forward in opposite direction for actuation and self-
cancellation to engage with the cancellation trigger and accordingly actuation and
self cancellation is achieved.
Fig. 3(b) is a side view of sub-assembly of switch cover, pawl, action slide
and spring to clearly show the position of action slide and cancellation pawl.
Fig. 4 and Fig. 5(a), 5(b) and 5(c) are explained together to have a clear
understanding of the function of a switch. Fig. 4 is a side view of sub-assembly of
lever, rotor, snap spring, snap plunger and horizontal pivot pin. Fig. 5(a), 5(b)
and 5(c) is a plan view and side view of sub-assembly of lighting contact,
terminals, base, contact slide, contact and spring. The working in Fig. 4 is
explained assuming that the lever is in center position corresponding to
headlamp dip beam actuations. The lever (5) engages with the contact carrier
22A or 22B shown in Fig. 5(a). The lighting contact plate (23) is held in position
by carrier 22A and 22B. The movement of lever 5(A) downward lifts the carrier
(22) in Fig. 5 (c) upward and moves lighting contact plate (23) pushed by spring
24 in Fig. 5(a) held by the carrier. This movement changes the electrical
connection making the high beam ON. Similarly, upward movement of lever 5(A)
in Fig 4 pushes the carrier (22) shown in Fig. 5(c) down and thereby making both
the high beam and low beam ON. This position is spring loaded. The action of
loading spring is achieved with the help of action plunger (17) and spring (18) in
Fig.4. This ensures that as soon as manual lifting of lever is released and the
switch return to middle position with only dip beam ON. In the base (9) all
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electrical terminals are riveted and on to which all electrical frets are fitted. The
headlamp switch (6A) in Fig. 5 (b) is connected to the terminals (i),(ii),(iii)and(iv).
Fig.6 shows the complete switch assembly enclosed in a housing (25),
which is used for mounting the switch on vehicle steering column.
Advantages of the invention:
1. This switch reduces the number of pivot joints/linkages due to which
switch actuation performance is achieved.
2. It is reliable and provides customer satisfaction.
3. The sliding contacts do not fall and hence chances of its failure are
less as compared to that of prior art.
4. It is more current rating and can be operated without relay.
5. It is more efficient and has multi utility functions.
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WE CLAIM:
An integrated combination switch assembly for use in heavy commercial
vehicle comprising of switch-actuating lever, which is assembled to a rotor by a
metallic horizontal pivot pin through riveting process; it also consists of action
plunger along with spring to get head/dim operation/snap feel of switch; the roller
and roller carrier along with spring are assembled on to the top of rotor; also an
actio'n plunger is assembled with spring to get engagement action for direction
indicator as well as self-cancellation mechanism when it is pushed by striker
bush through trigger / pawl and is further fitted on to the switch cover; the
Contact Pin is assembled with lighting fret in an automatic orbital riveting
machine to assemble with contact pin and is riveted into base; lighting contact
plate along with spring shall be assembled in contact slides in two places and is
fit to the base slot and is operated through the front portion of lever; a push
actuator horn push button is assembled at the end of the lever and accordingly
final assembly of the unit is made with two screws from bottom, which is locked
by a metallic pivot pin i.e. cover sub-assembly, base sub-assembly and lever
sub-assembly and are riveted from bottom to complete the entire assembly,
which is then housed in an enclosure to form a combination switch.

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