Handheld Controller with Upward LED Illumination
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Solution Overview
Problem
Conventional lighting devices attached to machine tools create shadows and uneven illumination, impairing visual checks due to structural obstructions and inability to provide portable illumination during manual operation.
Innovation Solution
A hand-held controller with an integrated illumination light source, such as a high-intensity light-emitting diode, that allows operators to input control signals and illuminate specific areas, ensuring reliable and safe operation by indicating operational control status through lighting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a fixed lighting device is attached to the machine tool, then the illumination lamp can be positioned to avoid shadows from the spindle and tool, but other structures (such as supply nozzle) arranged between the illumination lamp and workpiece create shadows that impair visual checking
Solution Approach 1:
The lighting function is segmented from the fixed machine tool structure and assigned to a portable handheld controller. This allows the lighting source to be independently positioned and moved to optimize illumination angles, avoiding shadows created by machine structures like supply nozzles while maintaining control functionality.
Solution Approach 2:
The lighting device transitions from a fixed position to a dynamic, movable position on the handheld controller. The operator can move the controller to different locations and angles, dynamically adjusting the lighting position to eliminate shadows from various machine structures while illuminating the work area as needed.
2Illumination intensity
If a fixed lighting device is attached to the machine tool, then illumination can be provided in the work area, but the lighting is concentrated directly below and around the lighting device, creating dark areas apart from that
Solution Approach 1:
The lighting device becomes dynamic and portable, allowing the operator to move it to different locations around the work area. This enables illumination to be dynamically redirected to different areas as needed, rather than being fixed in one location, improving overall work area visibility and accessibility.
Solution Approach 2:
The handheld controller combines multiple functions: it serves as both the control interface for machine operation and the lighting device. This multi-functionality allows the operator to simultaneously control the machine and illuminate different work areas by positioning the controller appropriately, eliminating the need for separate fixed lighting installations.
3Illumination intensity
If a portable lighting device is used to illuminate specific areas, then visual checking in dark areas can be improved, but a portable lighting device cannot be employed when the operator manually controls the machine tool with a manual pulse generator
Solution Approach 1:
The lighting function is merged with the manual pulse generator controller into a single integrated handheld device. This combination allows the operator to use one device for both controlling the machine and providing illumination, eliminating the conflict between using portable lighting and manual control operations.
Solution Approach 2:
The handheld controller becomes a universal device that performs both control functions (manual pulse generation) and illumination functions. This multi-functionality resolves the contradiction by allowing the operator to simultaneously or alternately use the device for both purposes without requiring separate equipment.
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
Enables efficient and safe manual operation by providing targeted illumination, preventing accidents and improving work conditions by ensuring adequate lighting regardless of machine tool configurations.
Implementation Method 1
an illumination light source, such as a high-intensity light-emitting diode
Data Source
AI summary
A manual pulse generator (1) attached to the control panel of a machine tool made up of: a spindle mechanism for holding a tool; a workpiece mounting mechanism; a feed mechanism for moving the spindle mechanism relative to the workpiece mounting mechanism along three orthogonal X-axis, Y-axis and Z-axis paths, a control device for controlling the feed mechanism, a control panel having control keys and a keyboard for inputting various types of data to the control device, and a display for displaying on a screen control state resulting from the control device. The manual pulse generator (1) is provided with a control section (11) for inputting a pulse signal to the control device, and a light-emitting diode (15) for illumination, which is provided on an upper surface thereof to emit light upwardly, and which lights only when a pulse signal can be input to the control device.