BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a time switch whereby on and off conditions of internally installed contact points control the operation of an electrical load according to a desired time schedule.

2. Description of Background Information

A conventional time switch, such as the type described in Japanese Kokai (laid open) Patent S63-29427, includes a modular structure assembled from a motor that rotates at a uniform speed, a ratchet gear driven by a gearwheel transmission powered by the motor, and a first gear that meshes with the ratchet gear. The time switch also includes a sub-dial that rotates clockwise at a rate of one revolution per hour relative to the rotation of the ratchet gear, a gear that meshes with a second gear attached to the rotating shaft of the sub-dial, a dial that rotates clockwise once during a twenty four hour period relative to the rotation of the sub-dial, a scheduling clip with a finger that projects from the circumference of a dial used to set a desired operating time schedule, and an internal contact point activating mechanism that opens and closes the contact points through contact with a contact element that is freely settable to a desired time. In the time switch of Japanese Kokai (laid open) Patent S63-29427, the ratchet gear, which is rotatably driven by motor torque supplied through the gearwheel transmission, rotatably drives the sub-dial through the sub-dial shaft. Although the dial is rotationally driven by meshing with the second gear on the sub-dial shaft, the sub-dial shaft rotates only in one direction due to the ratchet mechanism formed by the first gear and ratchet gear at the rotating sub-dial shaft. As a result, even though the sub-dial can be turned manually to set the time, it can only be turned in one direction, thereby making it time-consuming to set the time. For example, when changing the time schedule due to the enactment of daylight savings time, it would be easy to turn the sub-dial back one hour from a current setting of seven o'clock to a six o'clock setting. Because the sub-dial can only be turned in the clockwise direction, however, it must be advanced twenty three hours to effect the desired time change. As a result, changing the time becomes a time-consuming operation. Additionally, in the time switch described in JP 63-29427, a knob is provided to manually turn the rotating shaft to one of three positions which include (1) a position at which the contact points are turned â€œon and offâ€ in response to the scheduling clips, (2) a position at which the contact points are turned â€œonâ€ regardless of the scheduling clips, and (3) a position at which the contact points are turned â€œoffâ€ regardless of the scheduling clips.

Moreover, with this type of conventional time switch, there are times when there is no direct relationship between the scheduling clip and the position of the contact points directly after the dial has been manually turned.

SUMMARY OF THE INVENTION

Noting the drawbacks of the prior art described above, a feature of the present invention includes a time switch that allows the sub-dial to be manually rotated in either a clockwise or counter-clockwise direction to more conveniently set the time, and a mechanism that maintains a normal relationship between the scheduling clip and contact points.

An aspect of the present invention provides a time switch including a switch case; a dial rotatably attached to the face of the switch case, the dial rotatably driven at a uniform speed through a gearwheel transmission powered by a motor rotating at a uniform speed; scheduling clips including finger portions which project from the perimeter of the dial to determine a desired operating time; a cam shaft supported by the switch case; first cams projecting from the perimeter of a scheduling cam rotatably supported by the cam shaft, the scheduling cam rotatable through contact with respective finger portions of the scheduling clips; second cams projecting from the perimeter of a switching cam rotatably supported by the cam shaft, the switching cam rotatable in one direction together with the scheduling cam; contact points that switch between on and off positions relating to the rotation of the second cams on the switching cam; a ratchet mechanism provided within the gearwheel mechanism that does not slip when torque transmitted from the motor is sufficient to rotatably drive the dial, and slips when the dial is manually turned while being rotatably driven by torque transmitted from the motor; and a control knob provided on the cam shaft and external to the case, the control knob configured so that manual rotation of the control knob switches the contact points between on and off positions. Further, the time switch may include a switch control component configured to switch the contact points between an on condition in which the contact points are connected to each other and are unaffected by operation of the cam switch assembly, an off condition in which the contact points are separated from each other and are unaffected by operation of the cam switch assembly, and an automatic condition in which the contact points may be turned on or off by operation of the cam switch assembly. Further, indicator marks may be provided on the external surface of the case indicating the direction that the control knob is to be turned.

In a further aspect of the present invention, the time switch may include a contact point indicating assembly including an indicator mark on the control knob, an on display on the external surface of the case corresponding to indication on the control knob when the contact points are in an on condition, and an off display on the external surface of the case corresponding to indication on the control knob when the contact points are in an off condition. Further, the switch control component may include a switch bracket including a ridge provided thereon; and a plurality of channels provided in the case, the plurality of channels including a first channel configured to receive the ridge corresponding to the on condition of the contact points, a second channel configured to receive the ridge corresponding to the automatic condition of the contact points, and a third channel configured to receive the ridge corresponding to the off condition of the contact points. The switch control component may further include a lug provided on the switch bracket; and a window orifice provided in the case and configured to receive the lug in a plurality of positions including a first position indicating the on condition of the contact points, a second position indicating the automatic condition of the contact points, and a third position indicating the off condition of the contact points. Further, the time switch may include a directional arrow mark provided on the external surface of the case adjacent the control knob indicating the turning direction of the control knob.

A further aspect of the present invention provides a time switch including a switch case; a dial attached to the face of the switch case, the dial rotatably driven by a motor; scheduling clips which project from the perimeter of the dial to determine a desired operating time; a cam shaft supported by the switch case; cams rotatably supported by the cam shaft; contact points that switch between on and off positions relating to operation of the cam assembly; a ratchet mechanism that does not slip when torque transmitted from the motor is sufficient to rotatably drive the dial, and slips when the dial is manually turned while being rotatably driven by torque transmitted from the motor; and a control knob provided on the cam shaft and external to the case, the control knob configured so that manual rotation of the control knob switches the contact points between on and off positions.

The present invention allows the time to be more conveniently set by manually turning the dial in either the motor-driven direction or the opposite direction thereto. This is made possible by the torque transmitted from the manually turned dial causing the ratchet mechanism to slip, thus preventing the transmission of torque from the dial to the motor. Moreover, the scheduling clips and contact points can be set to a mutually aligned condition by turning the contact points â€œonâ€ or â€œoffâ€ , without turning the dial, by manually turning a control knob provided on the end of the cam shaft which projects outside of the case. Additionally, the present invention allows the condition of the contact points to be easily discerned from the radial position of the control knob.

Accordingly, the present invention provides improved operation of the time switch by allowing the time to be set by manually turning the dial in either the direction in which it is rotated by the motor, or the direction opposite thereto, at the time when the dial is being rotatably driven by the motor. This is made possible by the slippage of the ratchet mechanism preventing torque from the manually turned dial from being transferred to the motor. In addition, the contact points can be opened or closed, without turning the dial, by manually turning the cam shaft, through the manual turning of the control knob, to normally align the scheduling clip setting with the contact points.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, and other objects, features and advantages of the present invention will be made apparent from the following description of the preferred embodiments, given as nonlimiting examples, with reference to the accompanying drawings in which:

FIG. 1 is an exploded partial perspective view, as seen when viewed from above the clock mechanism, of the time switch of a first embodiment of the present invention;

FIG. 2 is an exploded partial perspective view, as seen when viewed from below the clock mechanism, of the time switch of the embodiment of FIG. 1;

FIG. 3 is a perspective view of the time switch of the embodiment of FIG. 1 with an external case;

FIG. 4 is a cross sectional view of the gearwheel transmission of the time switch of the embodiment of FIG. 1;

FIG. 5 is an exploded perspective view of the switch cam assembly of the time switch of the embodiment of FIG. 1;

FIG. 6a is a cross sectional view switch assembly of the time switch of the embodiment of FIG. 1;

FIG. 6b is a cross sectional view of the switch assembly of the time switch of the embodiment of FIG. 1;

FIG. 7a shows the operation of the contact points of the time switch of the embodiment of FIG. 1;

FIG. 7b shows the operation of the contact points of the time switch of the embodiment of FIG. 1;

FIG. 8a shows the ninth shank gear housed within the ninth gear of the time switch of the embodiment of FIG. 1, as viewed from below;

FIG. 8b shows the ninth shank gear housed within the ninth gear of the time switch of the embodiment of FIG. 1 at their point of mutual contact;

FIG. 9a shows a variation of the ninth shank gear housed within the ninth gear of the time switch of the embodiment of FIG. 1, as viewed from below;

FIG. 9b shows an exploded view of the ninth shank gear of FIG. 9a housed within the ninth gear at their point of mutual contact;

FIG. 10a shows a variation of the ninth shank gear housed within the ninth drive gear of the time switch of the embodiment of FIG. 1 as viewed from below;

FIG. 10b shows an exploded view of the ninth shank gear of FIG. 10a housed within the ninth drive gear of the time switch of the embodiment of FIG. 1 at their point of mutual contact;

FIG. 11 is a block diagram of the time switch of the embodiment of FIG. 1;

FIG. 12 is an external perspective view of a second embodiment of the time switch of the present invention; and

FIG. 13 is a block diagram of the time switch of the embodiment of FIG. 12.

DETAILED DESCRIPTION OF THE INVENTION

The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description is taken with the drawings making apparent to those skilled in the art how the forms of the present invention may be embodied in practice.

The following will describe embodiments of the invention with reference to the accompanying drawings. The first embodiment of the present invention will be described with reference to FIGS. 1 through 11 with positional references (top, bottom, right, left) being based on FIG. 3 unless otherwise specified.

As shown in FIG. 3, switch case 10 of time switch â€˜Aâ€™ is formed as an assembly of main case 11 and sub-case 12, main case 11 housing mechanical clock mechanism 1, and sub-case 12 housing externally exposed screw-type input-output terminal portion 6 and internally located relay drive circuit 8 (to be described subsequently) that drives relays 7a and 7b. Switch case 10 of time switch â€˜Aâ€™ is housed within outer case 14 which includes box-shaped lower case 13, of which the top portion is open, and an upper case (not shown in the drawing) that covers the open top portion of lower case 13. Switch case 10 is placed on the floor of lower case 13, and is secured in position by multiple projecting ribs 13a, notches 10a which are formed on at least three sides of switch case 10, tabs 13b that extend inward from the sidewalls of lower case 13 into notches 10a, and lock fingers (not shown) formed on the floor of lower case 13, the tips of the lock fingers being formed as hook parts that join to notches 10a. Switch case 10 is placed over ribs 13a, and tabs 13b connect to notches 10a and the hook parts, thus securely attaching switch case 10 to the floor of lower case 13. Alternatively, switch case 10 may be secured to outer case 14 through the use of any suitable devices such as, for example, screws or other such mounting hardware.

Time switch â€˜Aâ€™ is equipped with the electrical circuit shown in FIG. 11. Clock mechanism 1, which is installed in main case 11, is equipped with synchronous motor 2 that rotates at a uniform speed of 600 rpm synchronized with the frequency of commercially supplied electrical power. Alternatively, instead of the synchronous motor 2, the present invention may include any suitable motor such as, for example, a stepping motor controlled by the output of a crystal-driven oscillating circuit.

Gearwheel transmission 3 reduces the speed of synchronous motor 2 at a ratio of 864,000/1 to drive dial 4, which is located at the center of the front surface of main case 11, at a rate of 1/1,440 rpm. In other words, dial 4 rotates once every 24 hours for the 24-hour time switch described in this embodiment. Therefore, setting the desired time schedule through the placement of scheduling clip 17 on dial 4 will result in contact points 5 opening and closing, according to the time schedule, in order to generate operating signals.

Input-output terminal portion 6, which is provided on sub case 12, is equipped with a pair of electric power terminals T11 and T12 that connect to a commercial electricity power source. This embodiment also includes two pairs of load terminals, T21 and T22, and T23 and T24, which are able to control two electrical loads. Load terminals T21 and T22, and load terminals T23 and T24 are controlled by the operation of contact points within load control relays 7a and 7b respectively, the contact points being opened and closed through the operation of relay drive circuit 8. Relay drive circuit 8 is made up of AC voltage drop circuit 8a which acts as a transformer to drop the source voltage, rectification circuit 8b which rectifies the output of AC voltage drop circuit 8a to output a DC voltage, and relay voltage circuit 8c which lowers and smooths the DC voltage from rectification circuit 8b so that relays 7a and 7b receive the required voltage. One input terminal of relay drive circuit 8 is connected to power terminal T11 through contact points 5, and the other input terminal is connected to power terminal T12. Therefore, when contact points 5 go â€œonâ€ according to the set time schedule, electrical power is supplied to activate relays 7a and 7b.

The following will describe the structure of clock mechanism 1 with reference to the accompanying drawings. FIG. 2 shows an exploded perspective view of the components including clock mechanism 1 which is installed within main case 11. Clock mechanism 1 is made up of multiple gears 32 through 41, gear shafts 42, spring arms 51 and 52 to which contact points 51a and 52a are attached, switch bracket 53 which is used to select the operating mode, cam switch assembly 60 which is used to manually connect or separate the contact points and, as will be described subsequently, to connect or separate the contact points according to the time schedule set by scheduling clip 17, the components being installed and aligned in parallel with the front wall of main case 11 between center cover 30 and main case 11. Moreover, while center cover 30 is attached to main case 11 by screws 25 inserted through holes in center cover 30 and into threaded bores provided in bosses 26 located on the rear surface of main case 1, center cover 30 may also be attached to main case 11 through any suitable device such as, for example, interlocking members.

The following will describe gearwheel transmission 3 with reference to FIGS. 2 and 4. Synchronous motor 2, to which first pinion gear 31 is attached to the shaft thereon, is provided on the rear surface of center cover 30, first pinion gear 31 meshing with second gear 32 through a hole provided in center cover 30. Gears 32 through 38 are rotatably supported on gear shafts 42 located between main case 11 and center cover 30, and on gear shaft 43 that extends from the rear surface of main case 11. Ninth drive gear 39 is rotatably supported by step shaft 24. A circular recess is formed within the rear side of ninth drive gear 39, and ratchet teeth 39a are formed on the inner circumference of the circular recess in the form of multiple uniformly spaced triangular teeth, as shown in FIG. 8a. Ninth pinion gear 41 is a structure formed of L-shaped pawls 41a, which extend at uniform intervals from the perimeter of the shank part of ninth pinion gear 41 in a configuration of angled spokes, mesh with multiple ratchet teeth 39a. Ninth pinion gear 41 is fixedly attached to step shaft 24 through interference fitting, gluing, welding, or other desired attachment methods so that gear 41 rotates together with step shaft 24, and the tip of each pawl 41a engages ratchet teeth 39a to form the ratchet mechanism. Ninth pinion gear 41 connects to ninth drive gear 39 through the ratchet mechanism with pinion gear 41b of ninth pinion gear 41 being in mesh with minute gear 40. Further, circular recessed part 11a is formed within the front part of main case 11 as a housing for housing dial 4, and gear 40a of minute gear 40 is inserted, rear side first, into recessed part 11a, through aperture 11c which is formed in the floor of recessed part 11a. Gear 40a, which projects from the front surface through aperture 11c, meshes with gear 15e of dial base 15 as will be subsequently described.

With gearwheel transmission 3 thus constructed, the rotational torque of first pinion gear 31, which is attached to and rotatably driven by the output shaft of motor 2, is transferred to ninth drive gear 39 through second gear 32, third gear 33, fourth gear 34, fifth gear 35, sixth gear 36, seventh gear 37, and eighth gear 38. The rotation of ninth drive gear 39 is conveyed to ninth pinion gear 41 through the ratchet mechanism, and the rotation of ninth pinion gear 41 is conveyed to sub-dial 20 through step shaft 24 and also to dial 4 through minute gear 40, thus turning both sub-dial 20 and dial 4 in a clockwise direction. As synchronous motor 2 rotates at a speed synchronized to the frequency of commercial electric power, gearwheel transmission 3 reduces the speed of the motor to a point where sub-dial 20 rotates once per hour, and dial 4 rotates once in 24 hours. Further, rotational restricting cam 44, which is provided at fourth gear 34, is provided to restrict the direction that sub-dial 20 and dial 4 are rotatably driven by motor 2 to only a clockwise direction. Although the rotational direction of fifth gear 35 is restricted, rotational restricting cam 44 would not be needed if motor 2 were the usual type that rotates in only one direction.

The following will describe contact points 5 and cam switch assembly 60 with reference to FIGS. 2, 5, 6, and 7. As shown in FIG. 1, spring arms 51 and 52 are rectangular metal members into which an S-shaped portion is bend-formed at the mid-point, and each S-shaped portion is secured within main case 11 by being pressed into channel 27 formed therein. Mutually opposing contact points 51a and 52a are formed on the free ends of spring arms 51 and 52. Flange 51b extends from the lower part of the end of spring arm 51 (the side of spring arm 51 opposite to the front wall of main case 11) as the part of spring arm 51 that contacts lower cams 62c of switching cam 62, described below. Flange 52b extends from the upper part of the end of spring arm 52 as the part of spring arm 52 that contacts an upper cam 62b of switching cam 62.

Switch bracket 53, which may be formed from any suitable material such as, for example, molded from synthetic resin, includes lug 53a that is inserted into window orifice 11d in main case 11 with switch bracket 53 provided within slide channel 11e, thus allowing switch bracket 53 to slide within the limits of window orifice 1d to any of three positions located by ridge 53b inserted into one of three channels 11f formed on main case 11. In other words, lug 53a can be switched between three positions. With lug 53a placed at the middle â€œautomaticâ€ position, the motor-driven or manual rotation of dial 4 results in the rotation of switching cam 62 of cam switch assembly 60, described below, and the bendable closing or opening of contact points 51a and 52a on spring arms 51 and 52 (automatic mode). Sliding lug 53a to the â€œoffâ€ position, a position where switch bracket 53 is at one end of its traversable limit, results in a projection on switch bracket 53 pushing spring arm 51 away from spring arm 52, thus separating contact points 51a and 52a (an â€œoffâ€ condition) and rendering them unaffected by the operation of scheduling clip 17 (which projects from the perimeter of dial 4) and cam switch assembly 60. Also, sliding lug 53a to the â€œonâ€ position, the position where switch bracket 53 is at the other end of its traversable limit, results in a projection on switch bracket 53 pushing spring arm 52 toward spring arm 51, thus connecting contact points 51a and 52a (an â€œonâ€ condition) and rendering them unaffected by the operation of clip 17 (which projects from the perimeter of dial 4) and cam switch assembly 60. â€œOff,â€ â€œAuto,â€ and â€œOnâ€ markings 11g are provided on the front of main case 11 to easily identify the position of lug 53a.

Further, cam switch assembly 60 includes cam shaft 61, switching cam 62, scheduling cam 63, thrust washer 64, coil spring 65, E-clip 66, and knob 67. Thrust washer 64 may be any suitable device such as, for example, a commercially known â€œpoly-slider washerâ€ . Cam shaft 61 is rotatably supported between main case 11 and mid-cover 30, one end being supported by bearing bore 28 at the perimeter of recessed part 11a of main case 11, and the other end being rotatably supported by a bore in mid-cover 30. Open part 29 is formed at the inner perimeter of recess 1a at the bearing bore 28 location in order to expose off-cam 63b and on-cam 63c on scheduling cam 63.

Switching cam 62, which may be formed of any suitable material such as, for example, molded synthetic resin, incorporates cylindrical part 62a into which cam shaft 61 is press fit, and four upper cams 62b that extend radially from the upper portion of shank 62a at uniform intervals. The purpose of upper cams 62b is to contact flange 52b of spring arm 52. Switching cam 62 also incorporates four lower cams 62c that extend radially from the lower portion of shank 62a at uniform intervals, the purpose of lower cams 62c being to contact flange 51b of spring arm 51. Clutch teeth 62d are formed on one axial end of shank 62a facing the lower side of scheduling cam 63. Upper cams 62b and lower cams 62c form the second cams which, when viewed axially, display a radial offset of approximately 45 degrees between the upper and lower cams.

Scheduling cam 63, which may be formed of any suitable material such as, for example, molded synthetic resin material, is constructed approximately the same as switching cam 62, and includes cylindrical shank 63a into which cam shaft 61 is inserted, and four off-cams 63b that extend radially at uniform intervals from the upper perimeter of cylindrical shank 63a. The purpose of off-cams 63b is to contact clip finger 17c of scheduling clip 17 (hereafter referred to only as clip finger 17c) when scheduling clip 17 is tipped downward toward dial 4. Scheduling clip 17 contacts four on-cams 63c that extend radially at uniform intervals from the perimeter of the lower end of cylindrical shank 63a toward switch cam 62, the purpose of on-cams 63c being to contact clip finger 17c when scheduling clip 17 is tipped upward. Clutch member 63d, which engages clutch member 62d, is provided at the other end of shank 63a (the end facing switch cam 62). Off-cams 63b and on-cams 63c combine to form the first cam which, when viewed axially, demonstrates a radial offset of approximately 45 degrees between the two cams.

Cam switch assembly 60 is assembled by first press fitting cam shaft 61 into the hole in cylindrical shank 62a with clutch member 62d facing upward, and then pressing switching cam 62 over the bottom portion of cam shaft 61. Cam shaft 61 is then inserted into the hole in shank 63a, with clutch member 63d facing downward, thereby resulting in scheduling cam 63 being movable in the axial direction of cam shaft 61. Thrust washer 64 and coil spring 65 are then placed over cam shaft 61 after which E-clip 66 is secured in the groove (not shown in the drawing) on cam shaft 61. In this assembled condition, coil spring 65 presses scheduling cam 63 against switching cam 62 with clutch member 62d (of switching cam 62) engaged with clutch member 63d (of scheduling cam 63). Moreover, scheduling cam 63 is not able to move freely in the axial direction on cam shaft 61 as a result of being pressurized against switching cam 62 by coil spring 65, thus preventing unnecessary movement of cam shaft 61.

The clutch mechanism is formed from clutch member 62d of switching cam 62 and clutch member 63d of scheduling cam 63. When dial 4 rotates clockwise, thereby rotating scheduling cam 63 counter-clockwise through contact with clip finger 17c, the engagement of clutch member 63d (on scheduling cam 63) against clutch member 62d (on switching cam 62) results in switching cam 62 also rotating counter-clockwise. However, when dial 4 rotates counter-clockwise, thereby rotating scheduling cam 63 in a clockwise direction through contact with clip finger 17c, switching cam 62 does not rotate because scheduling cam 63 moves axially upward on cam shaft 61, in a direction against the pressure of coil spring 65, to a point where clutch member 63d (on scheduling cam 63) disengages from clutch member 62d (on switching cam 62).

Cam switch assembly 60 is constructed so that, regardless of the upward movement of scheduling cam 63 on cam shaft 61 that disengages clutch member 63d from clutch member 62d, the movement resulting from the counter-clockwise rotation of dial 4 causing clip finger 17c to push scheduling cam 63 in the clockwise direction, the outwardly raised position of clip head 17a brings clip finger 17c into contact with on-cam 63c, or the inwardly lowered position of clip head 17a does not take clip finger 17c out of contact with off-cam 63b, and the outwardly raised position of clip head 17a locates clip finger 17c so as not to not interfere with off-cam 63b, or the inwardly lowered position of clip head 17a locates clip finger 17c so as not to interfere with on-cam 63c.

Cam shaft 61 of cam switch assembly 60 is rotatably supported between mid-cover 30 and main case 11 with one end extending upward through and supported by bearing bore 28 in mean case 11. Knob 67 may be attached in any suitable fashion such as, for example, press fitting, gluing, or soldering to the tip of shaft 61 at the end of the shaft extending above bearing bore 28. Cam switch assembly 60 is easily installed to main case 11 due to its modular construction resulting from cam shaft 61 being press fit into switching cam 62, scheduling cam 63 being placed over cam shaft 61, and thrust washer 64 and coil spring 65 being secured on cam shaft 61 by E-clip 66. Cam switch assembly 60 may also be assembled without E-clip 66 through a structure in which switching cam 62 is press fit over cam shaft 61, and scheduling cam 63, thrust washer 64, and coil spring 65 are assembled to cam shaft 61 with spring 65 being compressed and secured in position by direct contact with the inner surface of main case 11 at the time cam switch assembly 60 is installed between main case 11 and mid-cover 30. Moreover, while this embodiment specifies a thrust washer installed between scheduling cam 63 and coil spring 65 in order to reduce friction generated therebetween by the pressure applied by coil spring 65, thrust washer 64 may be omitted if it is determined that the pressure applied by coil spring 65 will not cause excessive friction when scheduling cam 63 rotates. Further, while this embodiment specifies that cam shaft 61 be press fit into switching cam 62 and that scheduling cam 63 rotate freely on cam shaft 61, cam shaft 61 may be press fit into scheduling cam 63 and switching cam 62 may freely rotate on cam shaft 61.

With the previously described switch bracket 53 set to the automatic position, turning knob 67 of cam switch assembly 60 counter-clockwise will result in switching cam 62 rotating together with cam shaft 61, and as shown in FIG. 7a, turning knob 67 to an â€œonâ€ position will result in flange 52b of spring arm 52 moving off of the tip of an upper cam 62b into the valley between the cams, thus allowing spring arm 52 to be displaced toward spring arm 51 due the tensile energy inherent in spring arm 52. This brings a lower cam 62c of switching cam 62 into contact with flange 51b of spring arm 51, thus bringing contact points 51a and 52a into mutual contact as a result of the flexing movement of spring arm 51 toward spring arm 52.

Turning control knob 67 in one direction to the â€œoffâ€ position, as shown in FIG. 7b, will result in flange 51b of spring arm 51 falling off of the cam and into the valley between lower cams 62c of switching cam 62, and thus displacing spring arm 51 in a direction away from spring arm 52 as a result of the tensile energy in spring arm 51. At the same time, an upper cam 62b of switching cam 62 comes into contact with flange 52b of spring arm 52, thus flexing spring arm 52 in a direction away from spring arm 51 to separate contact points 51a and 52a. Further, turning control knob 67 in a direction opposite to the counter-clockwise direction of cam shaft 61, as driven by contact with clip finger 17c of scheduling clip 17 on the perimeter of dial 4, will bring flanges 51b and 52b (of spring arms 51 and 52 which are not in mutual contact) against the ends of lower cam 62c and upper cam 62b, respectively, and prevent cam shaft 61 from rotating, thus allowing control knob 67 to be turned only in a counter-clockwise direction. Because dial 4 does not turn when control knob 67 is manually rotated, clutch member 63d ratchets against clutch member 62d of switch cam 62, thus preventing the rotation of scheduling cam 63. The approximately cross-shaped indicator mark 67a on the end face of knob 67, and the provision of â€œONâ€ and â€œOFFâ€ markings 11j on the surface of main case 11 make it easy to discern the connected (on) or disconnected (off) status of contact points 5 through the rotational position of knob 67. Moreover, arrow mark 11h is provided adjacent to knob 67 to indicate that knob 67 is to be turned in a counter-clockwise direction to prevent knob 67 from being turned in the clockwise direction opposite to the direction of arrow 11h on knob 67, and to prevent unnecessary force from being applied to spring arms 51 and 52 when turning knob 67 in the direction opposite to the direction that spring arms 51 and 52 are normally displaced by switching cam 62. This mechanism thus prevents damage to spring arms 41 and 52.

The following will describe clock mechanism 1 which includes primarily dial 4, sub-dial scale 18, pointer 19, and sub-dial 20.

The dial 4 structure includes dial base 15, dial cover 16, and multiple scheduling clips 17. Dial base 15, which may be formed of any suitable material such as, for example, molded synthetic resin, includes dome-shaped platform 15a in which bearing bore 15b is formed at the center for the insertion of cylindrical bearing boss 11b which extends from the center of recess 11a in main case 11. Dial base 15 also includes perimeter lip 15c that extends upward from the sidewall of platform 15a. Dial cover 16, which may be formed of any suitable material such as, for example, a molded synthetic resin, includes circular plate-shaped perimeter flange 16a located at platform 15a, perimeter wall 16b extending downward from the edge of perimeter flange 16a, and lock finger 16c, formed on the underside of perimeter flange 16a, that locks to orifice 15d provided on dial platform 15. Scheduling clip 17, an h-shaped clip that may be formed of any suitable material such as, for example, molded synthetic resin, includes clip head 17a, L-shaped clip leg 17b that extends downward from clip head 17a, and clip finger 17c that extends outward beneath clip head 17a. Multiple scheduling clips 17 (96 in this embodiment) are placed along the perimeter of dial platform 15, and are able to swing thereon due to the horizontally extending portion of each clip leg 17b inserted between dial base 15 and the lower edge of perimeter wall 16b of dial cover 16. More particularly, tipping clip head 17a of scheduling clip 17 downward (toward the center of dial base 15) results in the tip of clip finger 17c moving upward into contact with off-cam 63b of scheduling cam 63, and tipping clip head 17a upward and outward results in the tip of clip finger 17c moving downward into contact with off-cam 63b of scheduling cam 63. Moreover, round hole 16d is openly formed within perimeter flange 16a of dial cover 16 concentric with bearing bore 15b in dial base 15, and a 24-hour scale is provided around the perimeter of perimeter flange 16a, in relation to clips 17, said scale being marked off in specific time increments such as, for example, fifteen minute increments. The approximately triangular-shaped current time position display 11i is provided adjacent to the scale on main case 11 to identify the scale as indicating the current time.

Dial 4 is housed within recess 11a by placing bearing bore 15b of dial base 15 over bearing boss 11b of in main case 11, and engaging a lock ridge (not shown in the drawings) formed on the inner perimeter of bearing bore 15b to bearing boss 11b, thus attaching dial 4 to main case 11 in a way that allows the rotating movement of dial 4 in a clockwise or counter-clockwise direction as viewed from above. Further, gear 40a of mushroom gear 40 projects through shaft orifice 11c, which is formed in the floor of recess 11a, and extends from front surface of main case 11 to mesh with gear 15e formed on the rear surface of platform 15a of dial base 15. Torque from motor 2 is conveyed to mushroom gear 40 through gearwheel transmission 3, thus dial 4 rotates together with mushroom gear 40.

A circular recess is formed within perimeter flange 16a of dial cover 16 within which circular plate-shaped sub-dial scale 18 is fixedly inserted so as not to rotate with respect to case 11. In other words, sub-dial scale 18 does not rotate. Hole 18a is formed in the center of sub-dial scale 18, and external gear 18b is concentrically formed around hole 18a. Moreover, a twelve hour time scale is inscribed on the upper surface of sub-dial scale 18 in specific time increments.

Sub-dial 20 is a dome-shaped member made from any suitable material such as, for example, transparent synthetic resin. Indicator line 21 is formed on the upper surface of sub-dial 20, and orifice 20a, a small approximately oval-shaped opening when viewed from above, is formed in the approximate center of the upper surface. By securing orifice 20a to tip 24a of step shaft 24 (tip 24a being formed to a small approximate oval-shape as viewed from above), sub-dial 20 and step shaft 24 become a single structure through which sub-dial 20 rotates in unison with step shaft 24. Step shaft 24 projects upward through orifice 20a in sub-dial 20, and lock ring 22 is secured to the tip of step shaft 24 to prevent the detachment of sub-dial 20. Moreover, sub-dial 20 may be press fit or bonded to step shaft 24 and thus eliminate the need for lock ring 22. Also, this embodiment specifies the attachment of decorative cap 23 to the upper surface of sub-dial 20 to visibly cover lock ring 22 and the tip of step shaft 24 at least to improve appearance.

Pointer 19, which is formed by mutually meshed external and internal gears 18b and 19a, is rotatably supported between sub-dial scale 18 and sub-dial 20. A circular boss (not shown in the drawings) formed on the underside of sub-dial 20 joins to the hole in the center of pointer 19, and due to the circular boss being eccentrically aligned to step shaft 24, pointer 19 orbits (eccentric rotation) around the perimeter of step shaft 24 while rotating itself. Because the number of teeth on outer and inner gears 18b and 19a are established at a ratio that advances pointer 19 through a one hour time increment (approximately 30 degrees) for each rotation of sub-dial 20, the time scale of sub-dial scale 18, pointer 19, and indicator line 21 combine to form a twelve hour clock able to display the current time.

The following will describe operation of the time switch of the present invention. Dial 4 rotates in a clockwise direction at a uniform speed with one or more scheduling clips 17 tipped outward at the desired position corresponding to the time during which the connected electrical load is be operated. As shown in FIG. 6a, clip fingers 17c extend from the perimeter of dial 4 and are thus able to press against off-cam 63b and on-cam 63c of scheduling cam 63, which is exposed through open part 29, and thus turn cam shaft 61 in 45 degree increments.

As shown in FIG. 7b, with clip head 17a raised outward and contact points 51a and 52a separated, clip finger 17c contacts on-cam 63c at the lower end of scheduling cam 63 and thus rotatably drives cam shaft 61 through a 45 degree arc. This results in upper cam 62b of switching cam 62 separating from flange 52b of spring arm 52, and lower cam 62c pressing against flange 51b of spring arm 51 to flex spring arm 51 toward spring arm 52, a movement that connects contact points 51a and 52b.

With contact points 51a and 52a in mutual contact, clip finger 17c, as shown in FIG. 7a, presses against upper positioned off-cam 63b (in this case, clip head 17a of scheduling clip 17 is tipped down and inward) which results in cam shaft 61 rotating through a 45 degree arc that allows flange 51b on spring arm 51 to fall off of lower cam 62c of switching cam 62, thus allowing spring arm 51 to spring back in a direction away from spring arm 51. At the same time, upper cam 62b presses against flange 52b of spring arm 52, thus causing spring arm 52 to flex away from spring arm 51 and separate contact points 51a and 52a.

Although scheduling clip 17 operates through the above described mechanism to activate the time at which it is desired to operate the desired electrical load, sub-dial 20 may still be manually rotated in a clockwise or counter-clockwise direction to set the current time.

When sub-dial 20 is manually turned in the clockwise direction, ninth pinion gear 41 also rotates clockwise through its connection to sub-dial 20 through step shaft 24. At this time, even though pawls 41a of ninth pinion gear 41 are engaged to ratchet teeth 39a on ninth drive gear 39, turning ninth drive gear 39 (on the motor side) from ninth pinion gear 41 requires more torque than it takes to rotatably drive the dial, thus causing pawls 41a of ninth pinion gear 41 to flex and ride over ratchet teeth 39a. As a result, torque from ninth pinion gear 41 is not transmitted to ninth drive gear 39, and only minute gear 40 turns counter-clockwise as a result of being in mesh with pinion gear 41b of ninth pinion gear 41. The counter-clockwise rotation of minute gear 40 drives dial 4 in a clockwise direction, thereby allowing the time to be set by turning sub-dial 20 to the desired time setting. Further, contact points 5 will open and close at this time through the contact of clip fingers 17 with off-cam 63b and on-cam 63c on scheduling cam 63 as a result of scheduling clips 17 projecting from the perimeter of rotating dial 4.

Conversely, if sub-dial 20 is manually turned in a counter-clockwise direction, ninth pinion gear 41 will turn counter-clockwise. The operation of the ratchet mechanism at this time will prevent the rotation of ninth pinion gear 41 from being conveyed to ninth drive gear 39, while only minute gear 40 will rotate due to the minute gear 40 being in mesh with pinion gear 41b of ninth pinion gear 41. The clockwise rotation of minute gear 40 rotatably drives dial 4 in a counter-clockwise direction, therefore allowing the time to be set by turning sub-dial 20 to the desired time. Also, while clip fingers 17c, which project from the perimeter of sub-dial 4, will contact off-cam 63b and on-cam 63c and thus turn scheduling cam 63 clockwise as sub-dial 4 is turned, switching cam 62 will not rotate due to the disengagement of clutch member 63d from clutch member 62d, and thus the opening or closing of contact points 5 is prevented.

As a result of locating the ratchet mechanism within the power transmission path of gearwheel transmission 3, ninth drive gear 39 (which is driven by motor 2) is able to rotatably drive ninth pinion gear 41 and thereby rotate dial 4 and sub-dial 20 when the torque applied against ninth drive gear 39 (on the motor side) by minute gear 40 (on the dial side) is not sufficient to cause slipping of the ratchet mechanism. Moreover, in cases where sub-dial 20 is manually turned in a clockwise or counter-clockwise direction, the rotation of sub-dial 20 and ninth pinion gear 41 causes the ratchet mechanism to slip, thus preventing torque from rotating ninth pinion gear 41 from being conveyed to ninth drive gear 39. Therefore, the time can be set by turning sub-dial 20 in either a clockwise or counter-clockwise direction because only dial 4 will rotate. When sub-dial 20 is turned in the counter-clockwise direction, the operation of the clutch mechanism integral to switch assembly 60 will result in scheduling cam 63 rotating disconnected from switching cam 62. As switching cam 62 is now stationary, the counter-clockwise turning of sub-dial 20 will not open and close contact points 5, thus preventing the application of pressure to spring arms 51 and 52 when switching cam 62 rotates in a direction opposite to its normal operating direction. This mechanism decreases the possibility of damaging spring arms 51 and 52. Moreover, the structure of gearwheel transmission 3 is not limited to that described in this embodiment, but may take the form of any power transmission structure in which a ratchet mechanism is incorporated between motor 2 and sub-dial 20. Further, gearwheel transmission 3 may be constructed to drive dial 4 and sub-dial 20 in a counter-clockwise direction.

The ratchet mechanism has been described as incorporating triangular ratchet teeth 39a formed on the inner perimeter of a circular recess which is formed within the rear side of ninth drive gear 39, and four L-shaped pawls 41a that extend in an angled spoke pattern from the surface of ninth shank gear 41, the angular tips of pawls 41a engaging ratchet teeth 39a at a 45 degree angle. The ratchet mechanism, however, is not limited to this structure alone, and may also be constructed, for example, as illustrated in FIGS. 9a and 9b. In this different ratchet structure, ninth shank gear 41 incorporates four S-shaped pawls 41c that extend at uniform intervals from the perimeter of the shaft portion with the triangular-shaped tips of pawls 41c contacting ratchet teeth 39a on a line approximately aligned with the radial intersection of the ratchet teeth base line. As shown in FIG. 10, the ratchet mechanism may also be constructed in the form of ratchet ring 41e which is attached to ninth pinion gear 41 through spoke parts 41d that connect to the shaft part, and triangular pawls 41f, which are formed as projections on ratchet ring 41e, that engage the ratchet teeth.

As shown in FIG. 6, this embodiment establishes the number of clutch teeth 62d and 63d on switching cam 62 and scheduling cam 63 respectively as eight teeth, which is the same number of â€˜off â€™ and â€˜onâ€™ cams 63b and 63c on scheduling cam 63. As a result of the eight clutch teeth 62d and 63d, the manual or motor 2-driven rotation of dial 4 in the clockwise direction, after dial 4 has been manually turned in the counter-clockwise direction, results in clip finger 17c of scheduling clip 17, which extends from the perimeter of dial 4, pressing against off-cam 63b and on-cam 63c to enable the opening and closing of contact points 5.

In other words, when dial 4 is rotated forward, either manually or by the operation of motor 2, clip finger 17c of scheduling clip 17, which extends from the perimeter of dial 4, presses against on-cam 63c or off-cam 63b of scheduling cam 63 which results in the rotation of scheduling cam 63 and switching cam 62. While contact points 5 open and close from the rotation of upper cam 62b or lower cam 62c on switching cam 62, because switching cam 62 and scheduling cam 63 are mounted to a single cam shaft 61, the total number of upper cams 62b and lower cams 62c (8 cams) on switching cam 62 must be the same as the total number of off-cams 63b and on-cams 63c (eight) of scheduling cam 63. Because this embodiment specifies that there be four off-cams 63b and four on-cams 63c on scheduling cam 73, cams 63c and 63b each rotate 45 degrees when struck by clip finger 17c. For example, if there were to be three off-cams 63b and three on-cams 63c on scheduling cam 63, scheduling cam 63 would rotate 60 degrees when an off-cam 63b or on-cam 63c is struck by clip finger 17c. Contact points 5 could not be opened or closed if switching cam 62 were to rotate 60 degrees from the rotation of scheduling cam 63. Therefore, in this embodiment, the total number of upper and lower cams 62b and 62c on switching cam 62 is established as a whole integer multiple (1-to-1 in this embodiment) of the total number of off-cams 63b and on-cams 63c of scheduling cam 63 so that switching cam 62 turns to the same rotational angle as scheduling cam 63 to bring contact points 63 in and out of mutual contact. Moreover, switching cam 62 and scheduling cam 63 may have a mutually different number of cams if rotatably supported on separate shafts.

In addition, when dial 4 is manually turned in the counter-clockwise direction, the clutch will slip to allow only scheduling cam 63 to turn in 45 degree increments. However, if the number of clutch teeth 62d on switching cam 62 and the number of clutch teeth 63d on scheduling cam 63 are established as a whole integer multiple of the total number of off-cams 63b and on-cams 63c on scheduling cam 63 (a multiple of 1 in this embodiment), clutch teeth 62d of switching cam 62 and clutch teeth 63d of scheduling cam 63 will interlock when scheduling cam 63 completes its arc of rotation. Therefore, the subsequent manual or powered (by motor 2) rotation of dial 4 in the clockwise direction will result in clip finger 17c of scheduling clip 17, which projects from the perimeter of dial 4, pressing against off-cam 63b or on-cam 63c of scheduling cam 63, and therefore making it possible to quickly rotate switching cam 62.

In other words, with contact points 5 having been switched to their â€œonâ€ state by an â€œonâ€ clip finger 17c, dial 3 is manually rotated in the counter-clockwise direction (the opposite direction to that driven by motor 2) so that the â€œonâ€ clip finger 17c that switched contact points 5 to their â€œonâ€ state passes scheduling cam 63, an â€œoffâ€ clip finger 17c passes scheduling cam 63, and the next â€œonâ€ clip finger 17c moves up to scheduling cam 63. During this time, scheduling cam 63 rotates approximately 45 degrees from contact with the â€œonâ€ clip finger 17c that switched contact points 1 to their â€œonâ€ state, and a further approximate 45 degrees from contact with the â€œoffâ€ clip finger 17c, thus rotating a total of 90 degrees while contact points 5 have remained in their â€œonâ€ state, and with an â€œonâ€ clip finger 17c at scheduling cam 63. Because clutch teeth 62d of switching cam 62 are engaged with clutch teeth 63d of scheduling cam 63, the manual or powered (by motor 2) rotation of dial 4 in the clockwise direction (the direction driven by motor 2) will cause an â€œoffâ€ clip finger 17c to press against off-cam 63b of scheduling cam 63, thus resulting in scheduling cam 63 and switching cam 62 rotating approximately 45 degrees to switch contact points 5 to their â€œoffâ€ state.

To offer an additional example, with contact points 5 having been switched to their â€œonâ€ state by an â€œonâ€ clip finger 17c, dial 4 is manually turned in the counter-clockwise direction to the extent that â€œonâ€ clip finger 17c, which has just switched contact points 5 to their â€œonâ€ state, moves past scheduling cam 63, an â€œoffâ€ clip finger 17c moves past scheduling cam 63, the next â€œonâ€ clip finger 17c moves past scheduling cam 63, and the next â€œoffâ€ clip finger 17c is brought up to the switching position. During this time, scheduling cam 63 rotates approximately 45 degrees from contact with the clip finger 17c that switched contact points 5 to their â€œonâ€ state, a further approximate 45 degrees from contact with the next â€œoffâ€ clip finger 17c, and a further 45 degrees from contact with the next â€œonâ€ clip finger 17c. Scheduling cam 63 has thus rotated a total of approximately 135 degrees with contact points 5 remaining in their â€œonâ€ state and with an â€œoffâ€ clip finger 17c now at the scheduling cam 63 position. If it is determined at this time that an â€œoffâ€ clip finger 17c is at scheduling cam 63, and it is desired that contact points 5 be switched to their â€œoffâ€ state, this can be done by manually turning knob 67 which, in this embodiment, allows contact points 5 to be quickly and forcefully opened or closed. After contact points 5 have been switched to their â€œoffâ€ state through the manual turning of knob 67 (as a result of clutch teeth 62d of switching cam 62 being engaged to clutch teeth 63d of scheduling cam 63) the manual or powered (by motor 2) rotation of dial 4 in the clockwise direction (the direction driven by motor 2) results in an â€œonâ€ clip finger 17c contacting on-cam 63c of scheduling cam 63, thus resulting in scheduling cam 63 and switching cam 62 rotating approximately 45 degrees to switch contact points 5 to their â€œonâ€ state.

Further, while this embodiment specifies that the respective number of clutch teeth 62d and 63d on switching cam 62 and scheduling cam 63 be equal, switching cam 62 may be formed with sixteen clutch teeth 62d, a number double that of the number of teeth (eight) of off-cam 63b and on-cam 63c of scheduling cam 63. In this case, even though there are eight clutch teeth 63d on scheduling cam 63 (the same number of teeth on off-cam 63b and on-cam 63c), turning dial 4 manually in the counter-clockwise direction will result in clip finger 17c, which projects from the perimeter of dial 4, turning only scheduling cam 63 to a rotational angle (approximately 45 degrees) corresponding to two clutch teeth 63d of switching cam 62. When scheduling cam 63 stops turning, clutch teeth 62d and 63d of switching cam 62 and scheduling cam 63 engage, after which the manual or powered (by motor 2) rotation of dial 4 in the clockwise direction makes it possible for switching cam 62 to rotate simultaneously with scheduling cam 63 at the time scheduling cam 63 begins rotating through contact with finger clip 17c which projects from the perimeter of dial 4.

By establishing the total number of clutch teeth 62d on switching cam 62 as a whole integer multiple of the total number of clutch teeth 63d on scheduling cam 63, the manual or powered (by motor 2) rotation of dial 4 in the clockwise direction, after dial 4 has been manually turned in the counter-clockwise direction, results in the mutual engagement of clutch teeth 62d and 63d of switching cam 62 and scheduling cam 63, thus making it possible to open or close contact points 5 through the operation of clip finger 17c of a scheduling clip 17 positioned at a time setting subsequent to the present time. Moreover, the provision of sixteen clutch teeth 62d on switching cam 62, a number twice that of the eight clutch teeth 63d on scheduling cam 63 (the same number of clutch teeth as the total number of clutch teeth on off-cam 63b and on-cam 63c), will provide the same effect as noted previously.

The following will describe a second embodiment of the present invention with reference to FIGS. 12 and 13. The first embodiment specifies knob 67 (through which cam switch assembly 60 can be manually turned) quickly open or close the contact points. This second embodiment, however, eliminates knob 67. Also, while the first embodiment describes time switch 10 as being a single structure separated into main case 11 in which clock mechanism 1 is housed, and sub-case 12 in which the input-output terminal part is housed, the second embodiment houses the clock mechanism and input-output terminal part in the same space, and does not use an external case in which time switch 10 is housed. Moreover, FIG. 13 is a block diagram describing the circuit structure used by the second embodiment in which contact points 5 are connected directly to load terminals T21 and T22 whereby the on-off operation of contact terminals 5 control the on-off operation of the load. Descriptions of structures, operations, and components of the second embodiment that are identical to those of the first embodiment have been omitted.

Although the invention has been described with reference to an exemplary embodiment, it is understood that the words that have been used are words of description and illustration, rather than words of limitation. Changes may be made within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the invention in its aspects. Although the invention has been described with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed. Rather, the invention extends to all functionally equivalent structures, methods, and uses such as are within the scope of the appended claims.

The present disclosure relates to subject matter contained in priority Japanese Application No. 2003-301888, filed on Aug. 26, 2003, which is herein expressly incorporated by reference in its entirety.