Design of double toggle switching mechanisms

•We investigate behavior of the actuation mechanism of different toggle switches.•A classification scheme for toggle based switch mechanisms is introduced.•A systematic design methodology is established to design double toggle mechanisms.•7 structural and 3 kinematic criteria are identified for double toggle mechanism.•Mechanical embodiment for a novel double toggle switch is developed.

Toggle mechanisms are ubiquitous in electrical switches. However, literature for their mechanical design is scarce. This paper defines and classifies the toggle phenomena observed during switching. The concept of double toggle introduced in this paper enables a systematic screening of kinematic structure for the suitability in high performance switches. Seven structural and three kinematic criteria are identified for this purpose. It is also demonstrated that each such feasible kinematic structure lends itself to multiple physical embodiments. Therefore, the theory and procedure presented in this work can be used for design of numerous kinematically distinct mechanisms. One representative mechanical embodiment for a novel double toggle switch, including mass and geometric shape of links has been included in the paper. The switching behavior of the design is validated using Pro/Mechanism™.