The Product

The TD1140 is a pendant-style wireless machine control and a variant in Eaton’s TD1100 series. Pendants hang from a strap around the operator’s neck or shoulder, which makes the width of the back of the device something operators notice over the course of a day.

PDE contributed the industrial and mechanical design for the TD1100 series, including the TD1140, as part of Eaton’s campaign to unify and expand their wireless controls lineup.

The Challenge

Width in the Wrong Place

Pendant controllers are worn, not just held. They sit against the operator’s body while the operator works, and the part that makes contact is the back of the device. The cross-section of that back surface has a direct effect on all-day comfort.

The brief for the TD1100 series called for a back profile that reduced the contact surface against the body, without compromising the structural integrity of the housing or the IP67 sealing that the full lineup requires. The TD1140 also needed to accommodate the new modular battery platform shared across Eaton’s updated product family.

Design Sketch of the TD1140
The Solution

A Narrower Pontoon

The back of the TD1140 housing uses a narrower pontoon shape. Rather than a flat slab, the back profile tapers to a narrower contact surface, reducing the footprint against the operator’s body while keeping the overall enclosure geometry rigid enough to meet drop and sealing requirements.

It’s a subtle change in cross-section but a noticeable one when the device is worn for a full shift. The pontoon form also gives the device a cleaner visual profile.

The TD1100 series was designed to support variants with different button counts to suit different customer requirements. The TD1140 carries that modular approach into the housing, which accommodates the updated battery interface alongside the full button layout.

The Technologies Behind This Build

Mechanical Design
SolidWorks Injection Molding IP67 Sealing Ergonomic Form Development Modular Battery Integration