Hall-Effect Joystick Sensor for Drift-Free Position Sensing

Solution Overview

Problem

Joystick sensors face issues with short service life and poor performance due to wear and electrical noise from contact between brushes and carbon films, leading to 'drift' problems in gaming applications.

Innovation Solution

A joystick sensor design incorporating a rocker assembly with magnets and Hall IC elements on a flexible circuit board, eliminating direct contact and friction, which improves signal stability and accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a metal with greater elasticity is used as the brush, then the contact between the brush and carbon film is improved, but the brush wears quickly and service life is shortened

Engineering Contradiction:

Improvecontact reliabilityVSAvoidbrush service life

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The patent replaces the mechanical contact-based brush and carbon film sensing system with a magnetic field-based detection system using Hall IC elements and magnets. This substitution eliminates the mechanical wear between brush and carbon film while maintaining the ability to detect rocker position, thereby resolving the contradiction between contact reliability and brush service life.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If a high-hardness carbon film is used, then the brush contact is improved, but the brushes wear out quickly generating large electrical noise

Engineering Contradiction:

Improvecontact reliabilityVSAvoidelectrical noise

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the mechanical contact-based brush and carbon film sensing system with a magnetic field-based detection system using Hall IC elements and magnets. This substitution eliminates the mechanical wear between brush and carbon film while maintaining the ability to detect rocker position, thereby resolving the contradiction between contact reliability and brush service life.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Duration of action of moving object

If a low-hardness carbon film is used, then brush wear is reduced, but the carbon film surface is ground to toner affecting electrical performance

Engineering Contradiction:

Improvecarbon film service lifeVSAvoidelectrical performance

Core Design Contradiction:

Duration of action of moving objectVSReliability

Solution Approach 1:

The patent replaces the mechanical contact-based brush and carbon film sensing system with a magnetic field-based detection system using Hall IC elements and magnets. This substitution eliminates the mechanical wear between brush and carbon film while maintaining the ability to detect rocker position, thereby resolving the contradiction between contact reliability and brush service life.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Device complexity

If contact-based sensing is used, then the structure is simple, but friction and wear cause short service life and drift problems

Engineering Contradiction:

Improvesensing structureVSAvoidservice life

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the mechanical contact-based brush and carbon film sensing system with a magnetic field-based detection system using Hall IC elements and magnets. This substitution eliminates the mechanical wear between brush and carbon film while maintaining the ability to detect rocker position, thereby resolving the contradiction between contact reliability and brush service life.

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 solution provides a stable and accurate electrical signal output, extending the service life and preventing malfunctions by avoiding contact-related wear and noise.

Implementation Method 1

the two Hall IC elements and a switch spring arrange on the flexible circuit board, positions of the two Hall IC elements respective corresponding to positions of the two magnet

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentUS12197241B2Joystick sensor

Publication Date: 2025.01.14 GUANGDONG K SILVER IND CO LTD

AI summary

A joystick sensor includes a housing, a reset assembly, a rocker assembly, a circuit assembly, the reset assembly, the rocker assembly and the circuit assembly are mounted on the housing; the rocker assembly includes two magnets, an upper rocker arm, a lower rocker arm, and a rocker body, one end of the upper rocker connected with one of the two magnets; one end of the rocker arm is connected with the other one of the two magnets, the other end of the lower rocker arm is secured a pressing block; the circuit assembly includes a flexible circuit board, two Hall IC elements, and a switch spring, the two Hall IC elements and the switch spring are arranged on the flexible circuit board, positions of the Hall IC elements respective correspond to positions of the magnets; a position of the switch spring corresponds to a position of the pressing block.