Simulation Analysis of the Structural Design and Parameter Optimization of Automotive Toggle Switches and Key Components

Abstract

In response to common issues with traditional automotive switches, such as poor contact of terminals, low durability, and weak vibration resistance, this paper proposes and designs a novel high-performance automotive toggle switch. Through structural design and parameter optimization, a new solution is provided to enhance the structural strength and service life of automotive electronic components. After completing three-dimensional modeling based on SolidWorks 2025, a full set of simulation analyses was carried out using ANSYS Workbench 2024 R2. After structural optimization, the maximum stress of the core valve stem decreased from 17.19 MPa to 14.877 MPa, a reduction of 13.5%; meanwhile, the fatigue life increased to 2.51 times that before optimization, indicating that for polycarbonate materials, a slight reduction in stress can significantly slow the rate of component damage accumulation. The switch’s first-order natural frequency is 1171.7 Hz, and a random vibration analysis of the switch was conducted according to the industry standard ISO 16750-3:2023. Under excitations covering the entire 2000 Hz frequency range, the switch structure did not show deformation or fatigue risks caused by resonance, indirectly confirming that vibration energy density is often more concentrated at low frequencies. This study not only completes the innovative design and performance verification of the novel toggle switch but also demonstrates that the comprehensive research methods employed provide a systematic analytical approach for developing high-performance, highly reliable automotive electronic components under stringent industry standards.