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Electronic Position Switch / Cam Switch / Rotary Limit Switch

Home Products  Sensor-Technology-Category  Position & Angle   Rotary Limit Switch

Rotary Limit Switch

Electronic Position Switch offers 1:1 Replacement for Rotary Limit Switch in cranes, hoist and steel rolling mill screw downs

1:1 Replacement for Rotary Limit Switch / Cam Switch

Geared Rotary Limit Switch

Key Benefits

  • Monitor position ranges
  • Modular, easy to set
  • Calibration via preset; Intuitive configuration
  • Replacement solution for mechanical rotary cam limit switches

Key Benefits

  • Ø 14 mm solid shaft (flange or foot mounting)
  • Up to 15 position switches, switching capacity 230 V AC/DC, 0.5 A
  • Resolution 13 bit singleturn / 15 bit multiturn
  • Options: Current output (4-20 mA) for real-time position data
  • Online-Request Contact
  • Real-time position data (4 – 20 mA)

Case Studies of Retrofitting Cam Switch with Electronic Position Switch

Steel Rolling Mills

Replacement of Cam Limit Switches on the screw downs in steel rolling mills gives better precision accuracy and saves costs

Retrofit obsolete mechanical cam limit switches on hoists and cranes without the use of PLC

Upgrade mechanical cam limit switch to electronic position switch to improve accuracy  

Why replace rotary limit switch with electronic position switch?

Heavy industry places stringent demands on the reliability and longevity of installed components. Experience indicates that rotary cam limit switches, still prevalent in many industrial settings for position monitoring, fail to meet all safety, precision, and user-friendliness criteria.

For instance, rotary cam switches often suffer from poor switching accuracy and cumbersome adjustment processes for switching points. This inefficiency disrupts industrial processes, leading to stoppages and extended downtimes due to the extra time and effort required for precise positioning.

Electronic position switches offer flexible position range monitoring solutions compared to rotary cam limit switches. As hoist limit switches they find applications in hoisting gear, crane technology, mining operations, as well as screw downs and side guides in steelworks. 

Electronic position switches frequently serve as straightforward replacements in legacy systems with rotary cam switches. Additionally, they seamlessly integrate into new systems. These switches ensure high accuracy and simplify system calibration through presets, easy switching point adjustments, and straightforward data storage.


FAQs on Electronic Position Switch / Rotary Limit Switch

What is a rotary limit switch or mechanical cam switch?

A rotary limit switch is a type of electromechanical switch used to control the movement of machinery or equipment within specific angular limits. It consists of a rotating shaft connected to the equipment whose movement needs to be controlled and a switch mechanism that is activated by the rotation of the shaft.

The switch mechanism typically consists of contacts arranged in such a way that they are engaged or disengaged based on the position of the shaft. When the shaft reaches a certain angle or position, the contacts are triggered, signaling the machinery to stop, change direction, or perform another predetermined action.

Rotary limit switches are commonly used in industrial applications where precise control over the movement of machinery is required, such as in cranes, conveyors, robotic arms, and other automated systems. They provide a reliable means of ensuring that equipment operates within safe and specified limits, helping to prevent damage and accidents.

What are the applications of geared rotary limit switch?

Geared rotary limit switches find applications in various industries and systems where precise control and positioning are required. 

Industrial Machinery: Geared Rotary limit switches are used in industrial machinery for precise control of movement, such as in conveyor systems, packaging machines, and assembly lines.

Automotive Manufacturing: Rotary control switches are employed in automotive manufacturing processes for controlling the movement of robotic arms, welding machines, and assembly robots.

Material Handling: Heavy duty limit switches are used in cranes, hoists, and other material handling equipment to control the movement of loads and prevent collisions.

Mining Equipment: Geared rotary limit switches are used in mining equipment for controlling the movement of conveyor belts, crushers, and other machinery used in the extraction and processing of minerals.

Power Plants: In power generation plants, geared rotary limit switches help control the movement of valves, dampers, and other critical components in boilers, turbines, and other equipment.

How does a mechanical cam switch / rotary limit switch work?

Selection depends on factors like temperature ranges, wavelengths, and suitability for industrial applications, with options ranging from compact sensors to high-performance thermometers. Standard interfaces facilitate direct use for process control.

What is a electronic position switch?

An electronic position switch is a device used for monitoring the position of machinery or equipment in industrial settings. Unlike traditional geared cam limit switches, electronic position switches utilize electronic components to detect and indicate the position of a moving part. These switches offer advantages such as higher accuracy, greater flexibility in monitoring position ranges, and easier integration into systems. They are commonly used in various industrial applications including hoisting gear, crane technology, mining operations, and steelworks for tasks such as position monitoring, limit sensing, and automation control.

Why replace mechanical cam switch with electronic position switch?

In scenarios where certain heavy duty limit switches used in cranes or hoists in tandem with outdated PLC systems which have either been phased out or are unable to be replaced for various reasons, a solution is needed to modernize the position switches seamlessly, without requiring additional construction work.

Enter the electronic position switch ERC 40 from Hübner Giessen. With this innovative solution, users can programmatically set precise switching points via software. The programming process is straightforward and swift. Moreover, the programmed values are securely retained within the system and are impervious to shock and vibration, ensuring reliability and stability in operation.


What are the benefits of electronic position switch over mechanical rotary cam switch?

Replacing mechanical rotary cam or limit switch with electronic position switch has many advantages. Electronic Position Switches provide higher switching accuracy and monitoring – also without PLC.

 Certain models of cam limit switches maybe obsolete and hence electronic position switches becomes a suitable option for 1 :  1 replacement

Electronic position switches provide higher positioning accuracy

The electronic position switch requires less setup and maintenance time.

Unlike mechanical cam limit switches they can be directly mounted  without distribution gear

Electronic position switches have higher switching accuracy compared to mechanical cam limit switches.

Also another advantage over cam limit switches is that they provide additional real-time position data

Can electronic position switch replace EOT crane limit switches?

Mechanical cam limit switches deployed in cranes or in conjunction with an obsolete PLC have either been discontinued or the devices cannot be replaced for other reasons.

Retrofitting the mechanical EOT crane limit switches to a state-of-the-art technology using electronic position switch can be done without extra construction effort and without converting to a (new) PLC at the same time

Additionally, real switches up to 230 V and 0.5 A – existing cables can be kept most of the time

The ERC 40 offers a suitable replacement system for many EOT crane limit switches and installation situations. This enables more flexibility, higher accuracy and less spare parts.

Why is the electronic position switch a suitable alternative for mechanical cam limit switches?

The electronic position switch ERC 40 from Hübner Giessen empowers users to effortlessly program precise switching points with high precision using software. This programming process is not only rapid and straightforward but also ensures that the programmed values are securely retained within the system, impervious to the effects of shock and vibration.

What are the benefits to upgrade / replace cam limit switches with electronic position switch at screw downs in rolling mills?

Select the IR sensor with an optimal temperature range, considering environmental conditions and ensuring compatibility with the measuring object’s material and

Ease in Setting Switching Points: While the outdated mechanical solution often presents challenges in setting switching points, the ERC 40 offers a much simpler alternative. Users can effortlessly adjust the screw downs to their desired positions for switching points and seamlessly transmit this information to the software through a drag-and-drop interface.

Automatic Data Logging: With data stored directly within the ERC 40 and accessible on a PC, customers can easily duplicate previously set switching points onto other devices as needed. By storing reference positions and preset configurations, users can conveniently align the ERC 40 with the application, particularly useful after roll changes or other adjustments.

Enhanced Position Data Accuracy: By eliminating the need for distribution gears and leveraging the superior precision of the ERC 40, the entire system benefits from significantly increased accuracy. This improvement ensures more reliable operation and precise control.

Real-Time Position Data: In addition to its primary functions, the ERC 40 also provides real-time position data through its current output (4–20 mA). This feature offers users valuable insights into the system’s performance, enhancing overall operational efficiency and control.


What are the benefits of retro-fitting over hoist limit switch for cranes with electronic position switches?

The heavy duty Electronic position switch ERC 40 is enclosed in robust housing for use in extreme ambient conditions.

It can be easily replaced for the hoist limit switch and offers customers the following benefits:

Compared to mechanical cam limit switches, this heavy duty position switch offers significantly higher switching accuracy when approaching end position limits

Electronic position switches result in much less downtimes

It provides user-friendly calibration via preset input

Unlike the mechanical cam limit switches, electronic position switches can save and import parameter data sets  and provide time-saving safety check (switch test function) •

Additionally with the electronic position switch real-time position data (4–20 mA output) is obtained

Finally the electronic position switch provides option to integrate status monitoring (temperature, speed, voltage, system limits and so on) with active signal output for time-saving identification in the event of a fault condition