One-Piece Joystick With Embedded Magnet for Cost-Effective 3-Axis Sensing
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Solution Overview
Problem
The high cost of manufacturing joysticks due to the use of multiple pieces in existing designs, such as gimbal and ball and socket mechanisms, limits their affordability and efficiency in sensing three-axis directional movement.
Innovation Solution
A one-piece construction joystick with a movable member extending from a shaft to a spherical portion, featuring a magnet off-center within the spherical portion and a three-axis Hall Effect sensor positioned underneath, allowing for cost-effective manufacturing through injection molding and axial rotation functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple pieces are used to manufacture the joystick (gimbal mechanism with main shaft, movable device, magnet), then the joystick can achieve three-axis directional movement sensing, but the manufacturing process becomes expensive and complex
Solution Approach 1:
The patent combines the magnet and spherical portion into a single integrated component. The magnet is directly embedded in the spherical portion, eliminating the need for separate mounting structures and alignment mechanisms. This merging reduces the number of parts from multiple components to essentially two main components (movable member with integrated magnet-sphere, and housing with sensor), thereby simplifying manufacturing while preserving the three-axis sensing capability through the magnet's hemispherical movement pattern.
2Measurement precision
If multiple pieces are used to manufacture the joystick (gimbal mechanism with main shaft, movable device, magnet), then the joystick can achieve three-axis directional movement sensing, but the manufacturing cost increases
Solution Approach 1:
The magnet and spherical portion are merged into a single component, which simplifies the manufacturing process. Instead of requiring precise assembly of multiple separate parts (main shaft, movable device, magnet), the invention uses a one-piece construction for the movable member with the magnet embedded in the spherical portion. This reduces assembly steps, minimizes tolerance stacking, and lowers manufacturing costs while maintaining the ability to detect three-axis directional movement through the magnet's movement along a hemispherical pattern.
3Adaptability or versatility
If the magnet is positioned off-center in the spherical portion, then the hemispherical movement pattern is achieved for three-axis sensing, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by positioning the magnet at a specific off-center location within the spherical portion. This localized positioning creates the desired hemispherical movement pattern when the spherical portion rotates, enabling three-axis sensing. The off-center position is deliberately designed to generate the correct flux density variations (Bx, By, Bz) as the magnet moves through its hemispherical trajectory, and this specific local configuration is what enables the versatile three-axis detection capability.
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
This design reduces manufacturing costs while enabling efficient three-axis directional movement detection and incorporating a light emitting diode for operator interface, enhancing detection and operation with axial rotation capabilities.
Implementation Method 1
A three axis sensor is disposed underneath, adjacent, and in spaced relation to the spherical portion and magnet of the movable member such that movement of the actuating member positions the magnet in a hemispherical pattern along the three axis sensor.
Data Source
AI summary
A joystick having a movable member that includes a shaft portion and a spherical portion wherein the shaft portion has a diameter less than the spherical portion. An actuating member is secured to the shaft portion of the movable member to provide actuation of the movable member. A magnet is disposed within the spherical portion of the movable member and positioned adjacent a three axis sensor such that the magnet moves in a hemispherical pattern along the three axis sensor to operate a device.