Injection-Molded Joystick Lever With Embedded Magnet Sensing
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Solution Overview
Problem
Existing joystick control devices for industrial applications face challenges with inaccurate measurements due to manufacturing difficulties in precise magnet placement, high production costs, and inadequate haptic feedback, especially in locked positions, which affects sensory immersion and durability.
Innovation Solution
A joystick design featuring a control lever with an embedded lower magnet manufactured through injection molding, forming a monolithic structure with pivotal protrusions to secure the magnet in place, combined with a lower sensor and locking mechanisms for precise angular position measurement and haptic feedback, reducing vibration and dislocation, and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the magnet is placed on a metal control arm, then the joystick can detect angular position, but manufacturing precision deteriorates due to difficulty in precise magnet placement
Solution Approach 1:
The patent merges the magnet placement function with the control arm structure by integrating the magnet directly into the control arm body. This eliminates the need for separate magnet attachment operations, ensuring precise and consistent magnet positioning relative to the control arm geometry, thereby resolving the manufacturing precision issue while maintaining measurement accuracy.
Solution Approach 2:
The patent replaces the mechanical attachment method (screws, adhesives, or clips) with an integrated structural design where the magnet is formed as part of the control arm. This substitution eliminates variability in magnet placement that occurs with mechanical attachment methods, achieving both precise measurement and manufacturability.
2Reliability
If additional operations are performed to attach the magnet to the metal control arm, then the magnet can be secured, but manufacturing cost increases
Solution Approach 1:
The patent combines the magnet attachment function with the control arm manufacturing process itself. The magnet is positioned and secured as an integral part of the control arm structure, eliminating the need for separate attachment operations. This reduces manufacturing steps, lowers labor and material costs, while maintaining secure magnet attachment for reliable operation.
Solution Approach 2:
The control arm structure is designed to self-secure the magnet through its geometric features and material properties, without requiring external attachment mechanisms. The magnet is held in place by the control arm's own structure, eliminating the need for additional fastening operations and reducing manufacturing complexity.
3Reliability
If a lock assembly is added to prevent movement of the control lever, then durability improves, but device complexity increases
Solution Approach 1:
The patent merges the locking function with the control lever structure by integrating the lock assembly into the control lever body. The locking mechanism is formed as part of the control lever's structural features, eliminating the need for separate locking components. This reduces device complexity while maintaining the durability and stability required for industrial applications.
Solution Approach 2:
The control lever structure is designed to serve multiple functions: it provides the control interface, houses the magnet for sensing, and incorporates the locking mechanism. This multi-functionality eliminates the need for separate dedicated locking components, reducing overall device complexity while ensuring control lever stability for enhanced durability.
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 cost-effective, durable, and secure joystick with improved haptic feedback and precise angular position sensing, reducing production costs and enhancing user immersion in industrial applications.
Implementation Method 1
said control lever having at least one embedded lower magnet is manufactured from plastic by the injection molding... said lower magnet is embedded within the pivotal protrusion to be in the proximity of said upper circuit
Data Source
AI summary
A joystick for controlling a machine comprising; a handle assembly allowed to rotate around a central axis extending along a longitudinal direction of the joystick, a control portion having a casing in which a lower circuit with a lower sensor is provided and a control lever attached to the said casing so as to move pivotally about at a pivot axis which extends perpendicularly to the longitudinal axis of the control lever. Advantageously, said control lever having at least one embedded lower magnet is manufactured from plastic by the injection molding; said control lever comprises: at least one pivotal protrusion extending outwardly from the control lever for bearing in a housing of a casing; said pivotal protrusion forming a monolithic structure with the control lever by said injection molding and in that said lower magnet is embedded within the pivotal protrusion to be in the proximity of said lower circuit.