Remote Control Orientation Estimation for Direction-Matched Pushbuttons
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Solution Overview
Problem
Operators of remote-controlled overhead cranes and machine tools face safety issues due to the mismatch between the direction of control device buttons and the actual movement direction, especially when the operator's orientation is opposite to the directional indicators, leading to potential accidents from misaligned movements.
Innovation Solution
A control device system utilizing a combination of a three-axis accelerometer, triaxial gyroscope, and magnetometer to estimate the attitude of the control device, filtering magnetic disturbances and dynamically reassigning button functions to match the operator's orientation, ensuring movements align with the intended direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic compass is used to provide orientation signals, then the calculation of control device orientation is improved, but magnetic disturbances from metallic masses distort the measurements and reduce reliability
Solution Approach 1:
A calibration phase is introduced as an intermediary process between the magnetometer and the orientation calculation. During this calibration phase, the control device is positioned in a reference orientation away from metallic masses, and calibration values are stored. During normal operation, these calibration values serve as a reference to compensate for magnetic disturbances, allowing the system to maintain reliable orientation measurements even when metallic masses are present.
Solution Approach 2:
The system changes the parameter being measured by using the difference between current magnetometer readings and calibration values. Instead of relying on absolute magnetic field measurements that are easily distorted, the system measures deviations from the calibrated reference state. This parameter transformation allows the system to maintain measurement precision while being robust against magnetic disturbances from metallic masses.
2Ease of operation
If the control device is hand-carried by the operator, then ease of operation is improved, but the control device orientation becomes unpredictable relative to the overhead crane directions
Solution Approach 1:
The system dynamically adapts the control functions based on the detected orientation of the control device. Instead of requiring the operator to maintain a fixed orientation, the system continuously monitors the control device orientation using the inertial platform and magnetometer, and automatically reallocates control functions to match the current orientation. This dynamic adaptation maintains ease of operation while ensuring accurate orientation alignment.
Solution Approach 2:
The system implements feedback by continuously monitoring the orientation of the control device relative to the overhead crane and automatically adjusting the control function allocation. The inertial platform and magnetometer provide continuous orientation data, which feeds back to the control unit to determine the appropriate reallocation of pushbutton functions, ensuring that the control device always responds in the direction the operator is facing.
3Reliability
If pushbutton functions are reallocated based on control device orientation, then safety is improved by preventing misaligned movements, but device complexity increases due to additional sensors and processing
Solution Approach 1:
The inertial platform serves multiple functions: it provides orientation data for pushbutton reallocation, detects when the control device is inverted (180° rotation), and enables automatic correction of control function allocation. By making this single component multi-functional, the system achieves improved safety without proportionally increasing complexity. The same hardware foundation supports multiple safety and control features.
Solution Approach 2:
The system automatically detects orientation mismatches and reallocates control functions without requiring external intervention or complex external systems. The control device self-corrects by using its own inertial platform and magnetometer data to determine when reallocation is needed and performs the reallocation autonomously. This self-service capability improves safety while minimizing the need for additional external sensors or processing systems.
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 system ensures that pushbuttons always correspond to the natural direction for the operator, enhancing safety by compensating for magnetic disturbances and maintaining accurate movement control regardless of the operator's orientation, thus reducing the risk of accidents.
Implementation Method 1
a three-axis accelerometer (34)
Implementation Method 2
a triaxial gyroscope (36)
Implementation Method 3
a magnetometer (38)
Data Source
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AI summary
A method of estimating an attitude of a control device for controlling operating machines, where the control device comprises a plurality of pushbuttons for controlling the movement of an operating machine along respective directions, the method comprising the following steps: - preliminary estimating the attitude of the control device using data from an accelerometer and a magnetometer onboard of the control device; - updating of the preliminary estimate of the attitude of the control device using data from a gyroscope onboard of the control device.