Magnetic PCB Control Lever Layout for Precise Rotation Sensing
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Solution Overview
Problem
Existing control levers in industrial and similar fields face issues with precision due to perpendicular angle sensors requiring additional components, separate sealing, and excess space, leading to reduced accuracy and increased complexity in production and operation.
Innovation Solution
A compact control lever design utilizing a single printed circuit board with independent springs and a C-shaped lever supporting member, featuring a magnetic member and cocking springs to prevent undesired positioning and maloperation, while eliminating the need for multiple sensors and reducing space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If perpendicular angle sensors are arranged in the control lever, then the control lever can detect control arm rotation, but the precision is reduced and additional components are required
Solution Approach 1:
The patent combines the magnetic member and the sensor into a single integrated assembly mounted on the control arm. The magnetic member is positioned at the end of the control arm while the sensor is mounted on the control arm body, eliminating the need for separate perpendicular sensors and their associated mounting components. This integration reduces component complexity while maintaining detection precision through direct magnetic field interaction.
2Reliability
If separate sealing measures are taken for multiple sensors, then each sensor is protected, but the device complexity and production difficulty increase
Solution Approach 1:
The patent implements a unified sealing approach where the control arm body housing encloses both the magnetic member and sensor assembly. The sensor is mounted within the control arm body through a single sealing interface rather than requiring separate sealing measures for multiple sensors. This reduces manufacturing complexity while maintaining reliability through comprehensive sealing of the entire assembly.
3Measurement precision
If multiple sensor projections emerge in the control lever, then multiple detection points are provided, but insertion into the device becomes difficult
Solution Approach 1:
The patent consolidates the magnetic member and sensor into a single integrated detection system with one projection emerging from the control lever. The magnetic member is positioned at the end of the control arm while the sensor is mounted on the control arm body, creating a single insertion interface. This maintains detection capability through the magnetic field interaction while significantly improving insertion ease by eliminating multiple protruding components.
4Manufacturing precision
If a convex first axle and concave second axle are used to position the IC, then the IC is precisely positioned, but excess space is created restricting board insertion
Solution Approach 1:
The patent eliminates the need for separate convex and concave axle structures by integrating the sensor mounting directly into the control arm body. The sensor is mounted on the control arm body in a planar configuration, removing the requirement for complex three-dimensional positioning features. This reduces the overall space requirement while maintaining IC positioning precision through direct mounting on the control arm body.
5Stability of the object's composition
If torsion spring arms are retained, then the spring control lever maintains its position, but friction detection system production is complicated
Solution Approach 1:
The patent integrates the torsion spring mechanism directly into the control arm assembly, with the spring mounted on the control arm body and the magnetic member positioned at the end of the control arm. This integration simplifies the friction detection system production by eliminating the need for separate spring arm retention features, while maintaining lever position stability through the magnetic coupling between the magnetic member and sensor.
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 enhances precision, security, and ease of production by ensuring accurate friction detection and preventing unauthorized access, with a direct connector outlet and effective friction mechanism, improving overall performance and reliability.
Implementation Method 1
a magnetic member fastened to an end of said control lever and suitable to interact with the sensor provided on the printed circuit board
Implementation Method 2
at least one cocking spring is provided at each opposite lateral end of the lever supporting member wherein the control arm has a cylindrical connection hole immediately above the magnetic member
Implementation Method 3
The control lever further comprises a C-shaped lever supporting member having an opened section facing to the printed circuit board and arranged to rotate about the longitudinal axis of the lever supporting member
Data Source
AI summary
The present invention relates to a control lever (40) for a heavy equipment comprising a body (13); a printed circuit board assembly (25) comprising a printed circuit board (21) having thereon at least one sensor; a lever holder (4) which has a central hole (4b), through which a control arm (1) is at least party engaged, wherein a control arm (1) is rotatable about its longitudinal axis (Y), and which has at least one cocking spring (10) at each end, a magnetic member (7) fastened to an end of said control lever (4) and suitable to interact with the sensor provided on the printed circuit board (21). Said control lever further comprises a lever supporting member (11) in the form of "C", which is arranged such that its opened section faces to the printed circuit board (21) and which is suitable to rotate about its longitudinal axis (Y), wherein the control arm (1) is engaged into a slot (11) provided at the center thereof, and at least one cocking spring (10) is provided at its each end.