Shaft assembly for rotary switch

An electrical propulsion system, comprising:

• a rotary switch assembly comprising first, second, third, and fourth electrical contacts and a shaft assembly, the shaft assembly comprising:
• a shaft machined from an electrically non-conductive material to form a one-piece monolithic construction, the shaft comprising a circumferential groove having a T-shaped cross-section;
• two conductive ring segments each made from an electrically conductive material, each conductive ring segment being adhesively bonded to the circumferential groove in a circumferentially spaced-apart manner, wherein each conductive ring segment has the T-shaped cross-section;
• two non-conductive ring segments each made from an electrically non-conductive material, and each non-conductive ring segment being adhesively bonded to the circumferential groove circumferentially between the conductive ring segments, wherein each non-conductive ring segment has the T-shaped cross-section;
• and
• wherein the first, second, third, and fourth electrical contacts are electrically contactable with the conductive ring segments and the non-conductive ring segments via rotation of the shaft;
• a first power supply providing power to the first electrical contact of the rotary switch assembly;
• a second power supply providing power to the second electrical contact of the rotary switch assembly;
• a first propulsion system receiving power from the third electrical contact of the rotary switch assembly;
• and
• a second propulsion system receiving power from the fourth electrical contact of the rotary switch assembly;
• wherein the shaft of the rotary switch assembly is rotatable to switch between first and second modes, wherein in the first mode, the rotary switch transmits electrical power from the first power supply to the first propulsion system and transmits electrical power from the second power supply to the second propulsion system, and in the second mode, the rotary switch transmits electrical power from the first power supply to the second propulsion system and transmits electrical power from the second power supply to the first propulsion system.

A method for making a shaft assembly for a rotary switch of a propulsion system, comprising:

• forming a shaft of the rotary switch, wherein the shaft is made from an electrically non-conductive material, the shaft comprising a circumferential groove having a T-shaped cross-section;
• forming a conductive ring segment made from an electrically conductive material, the conductive ring segment having the T-shaped cross-section;
• applying a bonding adhesive into the circumferential groove;
• and positioning the conductive ring segment into the circumferential groove against the bonding adhesive.