Four-Axis Mechanical Controller With Redundant Force-Feel Springs
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Solution Overview
Problem
Conventional vehicle control systems, particularly in environments like aircraft, are bulky and complex due to the inclusion of springs for force feel mechanisms, and lack fail-operational mechanisms, making them less efficient and more prone to failure.
Innovation Solution
A mechanical controller with a reduced form factor and complexity, incorporating a single spring for force feel mechanisms, a gimbal located proximal to the operator's hand, and redundant concentric springs, along with a damper system to reduce oscillation, providing independent and redundant force feel mechanisms across multiple axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional control sticks include springs for force feel mechanisms in each direction of movement, then force feel is provided, but the device becomes bulky and complex
Solution Approach 1:
The patent combines multiple force feel mechanisms into a single spring assembly that serves multiple axes (lateral, longitudinal, and directional). This single spring mechanism replaces what would traditionally require separate springs for each direction, reducing component count while maintaining force feel functionality across all movement axes.
Solution Approach 2:
The single spring assembly is designed to provide force feel mechanisms for multiple directions of movement simultaneously. The spring mechanism universally serves lateral movement, longitudinal movement, and directional rotation, eliminating the need for dedicated springs for each axis and reducing overall system complexity.
2Reliability
If conventional control sticks include multiple springs for each axis, then force feel is achieved, but the form factor increases
Solution Approach 1:
Multiple force feel functions are merged into a single spring assembly located within the grip. This consolidation eliminates the need for separate spring mechanisms for lateral, longitudinal, and directional axes, significantly reducing the overall volume required for force feel mechanisms while maintaining all necessary force feel capabilities.
Solution Approach 2:
The spring assembly is nested within the grip structure, utilizing the internal volume of the grip housing. This nesting approach allows the force feel mechanism to be compact and integrated rather than external and bulky, reducing the overall form factor of the controller.
3Reliability
If conventional control sticks are designed with multiple springs, then force feel is achieved, but manufacturing and assembly become more complex
Solution Approach 1:
The patent merges multiple force feel mechanisms into a single spring assembly, which significantly simplifies manufacturing and assembly. Instead of installing and adjusting multiple separate springs for each axis, the single spring assembly can be installed as one unit, reducing assembly steps and potential errors while maintaining force feel functionality across all movement directions.
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 mechanical controller achieves precise positioning feel with reduced size and complexity, enhancing safety through redundancy and simplifying vehicle operation by integrating fail-operational mechanisms.
Implementation Method 1
a spring assembly configured to provide a force feel mechanism for movement of the shaft in the lateral axis and the longitudinal axis
Implementation Method 2
a damper system to reduce oscillation
Data Source
AI summary
A mechanical controller provides four-axis control of a vehicle's position and movement. For example, the controller provides control of a vehicle's operations through a lateral axis, longitudinal axis, directional axis, and a grip axis (e.g., operating a thumbwheel of the mechanical controller that provides additional control inputs to the vehicle). The mechanical controller can provide independent force feel mechanisms in each of the lateral, longitudinal, and directional axes of movement. Additionally, the mechanical controller may provide a redundant force feel mechanism (e.g., for increased safety). For example, redundant springs and dampers may be incorporated in each axis's force feel mechanism. The mechanical controller may include a plunger and spring assembly to provide a force feel mechanism in the lateral and longitudinal axes. In addition to this spring force, surfaces of a contact region between the plunger and a plunger actuating plate may be shaped to produce force feel characteristics.