Adaptive One-Handed Joystick for Intuitive Excavator Control
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Solution Overview
Problem
Existing joystick control patterns for excavators require a steep learning curve and are not intuitive for one-handed operation, especially for operators with limited experience, and do not allow execution of additional motion commands.
Innovation Solution
A one-handed joystick with adaptive control featuring a state-of-the-art industrial joystick base, a rotary upper handle with a position sensor, and an adaptive controller that mimics the motions of an excavator, allowing for reduced hand and arm motions and additional command execution through a combination of rotatable rings, sensors, and solenoid control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional two-hand joystick control patterns (SAE or ISO) are used, then the excavator can be operated with existing control systems, but the learning curve is steep and the control motions are not intuitive for operators
Solution Approach 1:
The control system is segmented into multiple independent control elements: a first joystick for controlling the boom and stick, and a second joystick for controlling the bucket. This segmentation allows operators to control different excavator functions independently, making the control patterns more intuitive and reducing the learning curve while maintaining versatility across different operation styles
Solution Approach 2:
The patent introduces an additional control dimension by adding a second joystick that operates independently from the traditional single-joystick SAE or ISO patterns. This dimensional expansion allows for more natural one-handed operation and provides alternative control pathways that are more intuitive for operators with varying experience levels
2Adaptability or versatility
If traditional two-joystick control systems are used, then standard SAE or ISO motion patterns can be executed, but additional motion commands cannot be executed and one-handed operation is difficult
Solution Approach 1:
The control system achieves multi-functionality by enabling a single joystick to control multiple excavator functions (boom, stick, and bucket) through programmable motion patterns. This universal control approach allows execution of both traditional SAE/ISO patterns and additional custom motion commands, increasing versatility without proportionally increasing device complexity
Solution Approach 2:
The control system dynamically adapts between different control modes and motion patterns. The programmable controller can switch between traditional two-hand operation modes and one-handed operation modes, and can execute various motion patterns including traditional SAE/ISO patterns plus additional custom patterns, providing dynamic versatility responsive to operator needs
3Productivity
If traditional joystick control patterns are used, then existing control systems can operate, but the number of hand and arm motions required to operate the excavator is high
Solution Approach 1:
The patent merges multiple control functions into a unified programmable control system that can execute complex motion patterns with fewer physical motions. By combining boom, stick, and bucket control into programmable sequences, the system reduces the number of separate hand and arm motions required while maintaining full operational capability, thereby improving productivity and ease of operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adaptive joystick reduces the complexity of operating an excavator, making it easier for inexperienced operators by closely resembling excavator motions and enabling additional command functions, thereby improving operational efficiency and learning curve.
Implementation Method 1
The position sensor is preferably a PCAP (projective capacitive) touch sensor
Implementation Method 2
It is preferable to use a compression spring to bias the center and peripheral conductive contacts outward to contact the position sensor
Implementation Method 3
The adaptive controller outputs at least one control signal to at least one solenoid, which controls at least one hydraulic cylinder
Data Source
AI summary
An adaptive joystick preferably includes a rotatable cylinder bar, an outer base ring, an inner ring and an industrial joystick base. An adaptive controller receives an output from the adaptive joystick and outputs a control signal to a valve solenoid to control a hydraulic cylinder. Angle, depth and pressure sensors are preferably used to monitor a position of the hydraulic cylinder. The sensor outputs are fed into the adaptive controller. An inward wrist curl of the rotatable cylinder bar combined with a forearm pull rearward of the outer base ring are used to cause a digging motion. An outward wrist curl of the rotatable cylinder bar combined with a forearm push forward of the outer base ring are used to cause a dumping motion. A hand movement to the left is associated with swinging the excavator left. A hand movement to the right is associated to swinging the excavator right.