Control Lever Wiring Layout for Balanced Torque and Precision
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Solution Overview
Problem
Existing machine control operating elements are not compact, ergonomic, or robust enough for industrial environments, leading to operator fatigue and reduced service life due to uneven torque distribution and mechanical resistance.
Innovation Solution
The operating element features paired control line assemblies with separate connection points on a straight line through the central axis of the control lever, balancing torques and forces for intuitive and precise operation, and minimizing material fatigue by using smaller cross-section lines and spiral arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If control lines are arranged in a paired design with separate connection points on opposite sides of the central axis, then torque distribution is balanced and operational precision is improved, but device complexity increases due to the paired wiring harness arrangement
Solution Approach 1:
The control line arrangement is segmented into a paired design with first and second wiring harnesses, each having separate connection points on opposite sides of the central axis. This segmentation balances the torque distribution across the control lever, preventing rotational offset and improving control precision despite the increased structural complexity.
2Volume of moving object
If control lines are routed along the control lever to the receptacle, then the operating element remains compact, but mechanical resistance and material fatigue increase due to friction and bending
Solution Approach 1:
The wiring harness is designed with dynamic routing that allows it to flex and move with the control lever during operation. The paired arrangement with separate connection points enables the harness to accommodate lever movement without excessive friction or bending, reducing material fatigue while maintaining compact dimensions.
3Device complexity
If a single wiring harness is used for control lines, then device complexity is reduced, but torque distribution becomes uneven causing control lever offset and reduced operational intuitiveness
Solution Approach 1:
The patent employs a symmetric paired wiring harness design where the first and second harnesses are positioned asymmetrically relative to each other but symmetrically relative to the central axis. This creates balanced torque distribution that counteracts each other, preventing control lever offset and improving operational intuitiveness.
Data Source
AI summary
An operating element for operating a machine by an operator in which control lines for connecting the control lever with a control unit in at least a paired design is provided. A first wiring harness and a second wiring harness run along the control lever to the receptacle. The first wiring harness runs from a first starting point to the receptacle and the second wiring harness runs from a second starting point to the receptacle. The first starting point and second starting point are arranged at a distance from the receptacle. The first wiring harness at a first connection point is connected to the receptacle, and the second wiring harness at a second connection point is connected to the receptacle. The first and the second connection point are arranged separately from each other on a straight connecting line, and the connecting line runs through a central axis of the control lever.