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How to select the right pushbutton

What does a pushbutton do?

The term “pushbutton” is used to refer to two different things.

  1. The first is a specific type of button assembly that you actually push on a panel.
  2. The second is the general group of components, or mechanical man/machine interface products, which includes : including lights, selector switches, potentiometers — and pushbuttons — by which people interact with machines.

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What to consider when choosing a pushbutton

Size or diameter

The first thing to consider is the size or diameter of button that you are looking for. Typically, a 22mm pushbutton is used in light industrial applications such as machine building, panels, material handling, and conveyors. Whereas a 30mm pushbutton are usually a better fit for heavy industrial applications such as oil & gas, water/wastewater, industrial equipment, and chemical plants.

Style

The next thing that we consider is style. Pushbutton families come in several styles and can be selected to complement the design of your machine. They usually come with either silver or black bezels, which is the color surrounding the operator. Another style option is flush mount, which allows the button to blend into the surface of the machine, or surface mount in which the button stands off the surface of the machine.

Operator type

Next you need to select the operator type. The reason there are so many pushbutton types is because each style provides an answer to a field problem. We can categorize these styles into the following buckets:

An exposed button is raised further off the panel than other buttons. Often used for a machine’s most important function, such as “Stop".
 
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These are used when more than one control option is needed (e.g., HAND/OFF/AUTO). Selector switches are usually the preferred pushbutton when a maintained contact is needed.
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These are most often used for Stop and Emergency Stop pushbuttons. Very easy to actuate because they make such a big target.
 
 
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These are maintained contact pushbuttons that you push in and then twist to release. The Twist-to-Release is often used for “Stop” or “Emergency Stop.” The extra effort needed to restart a machine forces a more active decision on the part of the worker.
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Saves space and money by combining the function of a pushbutton and an indicating light. Even though the button contains both an operator and a light, these are actually separate items that have to be wired separately inside. For example, the pushbutton might connect to a starter, while the light is wired to a microchip that reads “the engine is running.
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Mounts in a standard hole size, although space must be left on the panel for the lever action. Because the joystick extends outwards and often corresponds to the direction of movement sought, it is easy and intuitive to use.
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The button is flush with its housing. Direct pressure must be applied to actuate flush pushbuttons; they are not easily bumped into changing state. Often used as a START button.
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These take prevention of unwanted operation one step further than flush pushbuttons by having a metal guard around the actuator portion of the button.
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These must be physically pushed in or pulled out to change status. Two-position maintained contacts for START/STOP or UP/DOWN. Three-position maintained or momentary for START/STOP/RUN or HAND/OFF/ AUTO functions.
 
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These are maintained contact pushbuttons that you push in and need a key to release. Often used for safety reasons; for example, to lock off a machine during maintenance.
 
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Often used for speed control because turning the dial varies the resistance (ohms).



 
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A combination of a selector switch and a pushbutton in one unit. The outer guard of the pushbutton rotates to two or more positions and provides different contact actions when the pushbutton is either free or pushed-in at each selector position.
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Don’t forget to think about its ease-of-use

Selecting the right pushbutton is only a piece of the design of the full machine interface. Making that interface as intuitive and easy-to-use as possible requires some strategic thinking. We’ve summarized all the learnings you need to take into account while designing an easy-to-use machine (interface) in a dedicated design guide. All you need to do is download it and read it.
Download the Design Guide: How to design an easy-to-use machine

Discover how Labor Shortage impacts machine designs

Learn how to design future-proof machine interfaces

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