Joystick Actuator with Mixed Active Passive Force Feedback
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Solution Overview
Problem
Existing joysticks for controlling machines and vehicles with passive force feedback are costly due to expensive mechanisms and optical sensors, lacking informative feedback about the machine or vehicle condition.
Innovation Solution
A joystick design incorporating an actuator with two degrees of freedom, utilizing a single electromotor and reduction gear for active force feedback in one plane and a spring-action reset device for passive feedback in a perpendicular plane, combined with a leaf-spring mechanism and Hall sensors for position detection, reducing costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two electromotors with reduction gears are used for active force feedback in both planes, then positioning precision and control accuracy are improved, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
The control space is segmented into two independent planes: the first plane (left-right motion) uses active force feedback with an electromotor and reduction gear for precise steering control, while the second plane (forward-backward motion) uses passive spring force feedback for acceleration/deceleration control. This segmentation allows each plane to use the appropriate level of complexity for its control requirements.
Solution Approach 2:
Different quality levels of force feedback are applied locally to different planes based on their specific control requirements. The first plane receives high-precision active force feedback with low-backlash reduction gear, while the second plane receives simpler passive spring force feedback, optimizing the overall system without unnecessary complexity.
2Reliability
If two electromotors with reduction gears are used for active force feedback in both planes, then control accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The control system is segmented into two planes with different accuracy requirements. Only the first plane (steering) requires high-precision active force feedback with an electromotor and low-backlash reduction gear, while the second plane (acceleration/deceleration) uses simpler passive spring force feedback, reducing overall manufacturing cost.
Solution Approach 2:
The patent replaces one expensive electromotor with a much cheaper spring mechanism for the second plane, accepting that the spring-based passive feedback is sufficient for acceleration/deceleration control without requiring the precision and cost of an electromotor.
3Measurement precision
If optical sensors are used for position detection, then measurement precision is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent replaces expensive optical sensors with simpler mechanical position detection methods, such as Hall sensors or mechanical position indicators, which provide sufficient accuracy for joystick control applications without the complexity and cost of optical sensing systems.
4Measurement precision
If reduction gear with high precision is used to eliminate backlash, then positioning precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
High-precision low-backlash reduction gear is applied locally only to the first plane where precise steering control is required, while the second plane uses a simpler reduction mechanism or direct spring force feedback, optimizing the balance between precision and complexity.
Solution Approach 2:
The patent introduces a torsion spring as an intermediary element between the reduction gear and the joystick mechanism, which not only provides force feedback but also helps compensate for backlash through its elastic properties, reducing the need for extremely high-precision gearing.
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 achieves a more economical and effective joystick with a mixture of active and passive feedback, enabling cost-effective series production while providing precise control for steering and acceleration/deceleration functions.
Implementation Method 1
a spring-action reset device for passive feedback in a perpendicular plane
Implementation Method 2
active force feedback from an electromotor and reduction gear
Implementation Method 3
reduction gear with a gear wheel that is supported on the output shaft of the electromotor
Implementation Method 4
a leaf-spring management which connects a pivoting lever to a joint part
Data Source
AI summary
A joystick for controlling the functions of machines and/or vehicles comprises an actuator which can be moved in different directions by means of a joint having preferably two degrees of freedom, wherein the back-and-forth motions of the actuator occurring in a first plane are subjected to an active force feedback in the form of an electromotor and a reduction gear, and the back-and-forth movement of the actuator which occurs in a second plane perpendicular to the first plane is subjected to a passive force feedback in the form of a sprung reset device. In order to make such a joystick which allows for a low-cost serial production, the invention proposes that the reduction gear is designed with low backlash and is connected on the output side to the actuator via a preferably leaf-spring assembly which connects a swing arm to a joint part.