by LROBBINS » 28 Oct 2017, 14:22
I'll take a stab at that last question. The most common way that end-of-travel switches work is that there's one for extended limit and one for retracted limit. They are normally closed and when pressed by a cam on the actuator the contacts open. Each one has a diode in parallel with the switch, however, so that even though the circuit is interrupted in one direction, it is bypassed in the other direction. So, for example, if the "extend" limit switch is pressed, it will not allow any more current to flow in the extend sense, but the diode will let current pass in the retract sense. If a diode has failed so that it no longer conducts, if you reach that limit you can't go back. Is that what your chair does? If it is, there's probably a bad diode. Oftentimes the switches and diodes are actually inside the actuator, so can be a bit of a pain to repair - but it can be done.
I very much doubt that the controller uses time to infer position. If the actuator has an encoder, it can count pulses of the encoder to know position, but then there'd still be wires connecting it to the control module. I've never seen this on a chair, but it's also possible to have position sensors inside the actuator. I think that there was also at least one chair that used a potentiometer that was moved by the seat to give position information. In any case, a thing to check is how many wires are in the cable that connects the actuator to the electronics. If there are more than two wires, there's something more than just a motor (and possibly internal limit switches) inside the actuator.