Gauge Shaft Control Handle for Linear Force-to-Signal Sensing

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Solution Overview

Problem

Existing weapon system control handles in legacy ground-based combat vehicles are complex, heavy, expensive, and lack a linear force-rotation relationship, resulting in slow operational response and inaccurate target selection.

Innovation Solution

The use of a gauge shaft with serrations and strain gauges to convert mechanical force into electrical signals, eliminating complex mechanisms and providing a linear force-rotation relationship, thereby improving operational response and accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional spring and cam mechanisms are used to convert commanding force into electrical signals, then the control handle can sense operational position and angle, but the system becomes complex, heavy, and expensive with slow operational response

Engineering Contradiction:

Improveoperational position sensing accuracyVSAvoidmechanism complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the conventional mechanical spring and cam system with a gauge shaft system that uses strain gauges to directly convert mechanical force into electrical signals. This substitution eliminates the need for complex mechanical linkages while maintaining position sensing capability and improving response speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention extracts and eliminates the unnecessary mechanical intermediate components (springs, cams, levers) from the force-to-signal conversion process. By directly measuring force on the gauge shaft, the system removes redundant mechanical elements that added complexity and inertia to the response.

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If complex cam and spring mechanisms are used to convert force into rotation angles, then a wide range of rotation angles can be achieved, but the weight and assembly labor increase

Engineering Contradiction:

Improverotation angle rangeVSAvoidcontrol handle weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The patent replaces mechanical angle conversion mechanisms with a direct force measurement system using strain gauges on the gauge shaft. This eliminates heavy mechanical linkages and reduces the overall weight of the control handle while maintaining the ability to detect full range of motion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If conventional mechanical mechanisms are used for force conversion, then the control handle can operate, but replacement time and maintenance cost increase

Engineering Contradiction:

Improveoperational reliabilityVSAvoidcomponent replaceability

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The invention segments the control handle into modular components, with the gauge shaft assembly being a distinct, replaceable unit. This modular design allows the gauge shaft and its associated components to be independently replaced without affecting other parts of the control handle, reducing maintenance time and cost.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If non-linear cam mechanisms are used to convert force into rotation, then the mechanism can achieve wide angle conversion, but the voltage output is not continuous and linear

Engineering Contradiction:

Improveforce-to-angle conversion capabilityVSAvoidvoltage output linearity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent replaces non-linear mechanical cam mechanisms with a linear strain gauge measurement system. The strain gauges provide a linear relationship between applied force and voltage output, eliminating the non-linearity inherent in cam mechanisms while maintaining the full range of motion conversion capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 gauge shaft system reduces complexity, weight, and cost while enhancing operational response and accuracy, allowing for quick and precise target selection.

Implementation Method 1

The gauge shaft includes a plurality of strain gauges... the strain gauges are configured to generate a voltage in response to deflection in a radial direction

Methodology Applied

Scientific EffectPiezoresistive Effect: Piezoresistive Effect

Data Source

PatentUS12578170B2Weapon system control handle gauge shaft

Publication Date: 2026.03.17 ELBIT SYSTEMS OF AMERICA LLC

AI summary

The devices and systems disclosed herein improve on existing weapon system control handles, by replacing complicated spring and cam components with a gauge shaft. The use of a gauge shaft eliminates unnecessary part-complexity and extra assembly labor. The use of a gauge shaft increases operational response and accuracy while decreasing cost and weight of weapon system control handles. Moreover, the gauge shafts can be readily repaired or replaced, reducing the overall costs of maintenance associated with damaged weapon system control handles. In alternative embodiments, a disk gauge is used in place of gauge shafts.