Industrial Vehicle Control Box Layout for Ergonomic Thumb Joystick Use
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Solution Overview
Problem
Traditional control box designs for industrial vehicles like aerial work platforms suffer from poor ergonomics, inadvertent operation, and difficulty in reading operational details, with operators often using joysticks for stabilization, leading to suboptimal operation quality and the need for additional large joysticks for secondary functions.
Innovation Solution
The design features guarded thumb joysticks, integrated grab handles with enabling mechanisms, an open center layout for improved visibility, integrated display surfaces, and ergonomic placement of secondary joysticks, allowing for proportional control using mini-joysticks or switches while maintaining a familiar layout, and incorporating ranging sensors for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional control box layout is used, then controls are readily accessible, but operators can inadvertently operate controllers by leaning against them or getting them caught in clothing
Solution Approach 1:
The patent introduces foot pedals as intermediary devices between the operator and the control system. The foot pedals require deliberate foot movement to activate, serving as a mediator that prevents inadvertent operation while maintaining control accessibility. The foot pedals are positioned on the floor to engage foot muscle memory, creating a natural barrier against accidental activation.
2Ease of operation
If traditional control box layout is used, then controls are positioned for reachability, but ergonomics are poor and operators use joysticks for stabilization
Solution Approach 1:
The control system is segmented into multiple independent control elements: hand levers for primary control functions, foot pedals for secondary functions, and a thumb-operated joystick for fine adjustments. This segmentation allows each control element to be optimized for its specific function and reduces the need for operators to use joysticks for stabilization, as proper hand and foot controls are provided.
Solution Approach 2:
The patent adds the vertical dimension by positioning foot pedals on the floor and hand levers at elevated positions. This multi-level arrangement improves ergonomics by distributing controls across different heights and planes, allowing operators to maintain proper posture and balance while operating the vehicle.
3Adaptability or versatility
If additional large joysticks are added for secondary functions, then control capability is improved, but device complexity and layout uniqueness increase
Solution Approach 1:
The foot pedals are designed to serve multiple functions: they can control secondary functions, provide operational mode selection, and serve as enabling mechanisms for primary controls. This multi-functionality eliminates the need for separate large joysticks for secondary functions, reducing overall control box complexity while maintaining versatility.
Data Source
AI summary
A control box and operator interface for an industrial vehicle includes a left thumb joystick controller, a right thumb joystick controller, and integrated handles positioned adjacent the left thumb joystick controller and the right thumb joystick controller, respectively. The integrated handles are ergonomically positioned relative to the left and right thumb joystick controllers such that when an operator grasps the handles, the operator's thumbs are naturally positioned adjacent the left and right thumb joystick controllers, respectively. An enabling mechanism is associated with each of the integrated handles and includes a switch that serves to activate operational functionality of the left and right thumb joystick controllers.