Rotary Haptic Control for Industrial Machine Axis Switching
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Solution Overview
Problem
Existing control devices for industrial machines with motion drives are not adequately operable or programmable, leading to inefficiencies and safety concerns in manual operation, as they often require complex mechanical components and predefined positions, which can result in errors and increased risk of machine damage.
Innovation Solution
A control device with a rotary actuator control element that includes a mechanically interactive rotational resistance generation means, coupled with an electronic evaluation and control device, allowing for variable rotational resistance adjustment and haptic feedback, enabling intuitive operation without predefined zero positions and reducing the need for separate return springs or sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional toggle switches with mechanical stops and return springs are used, then predefined switching states can be achieved, but the device complexity increases and reliability decreases due to mechanical wear and failure points
Solution Approach 1:
The patent replaces mechanical toggle switches with electrical/electronic switching elements (transistors, relays, or software-based switches) that have no moving parts. This substitution eliminates mechanical wear, mechanical stops, and return springs, thereby increasing reliability while reducing device complexity. The electrical switching elements can be controlled by logical conditions or sensor inputs, providing the same switching functionality without mechanical components.
Solution Approach 2:
The invention extracts and removes the mechanical components (toggle switch, mechanical stops, return springs) from the system, retaining only the essential switching function through electrical or software-based mechanisms. This extraction eliminates the sources of mechanical failure while preserving the core functionality of switching between predefined states.
2Reliability
If complex mechanical components and predefined positions are used in control devices, then switching states can be achieved, but operational errors increase and safety decreases
Solution Approach 1:
By replacing mechanical components with electrical and software-based control systems, the patent eliminates mechanical failures that could lead to safety issues. The software-based control can implement logic that prevents erroneous operations, validates input conditions, and provides safer operational sequences, thereby improving safety without compromising ease of operation.
Solution Approach 2:
The invention incorporates feedback mechanisms through sensors and control logic that monitor system state and provide real-time information to the control device. This feedback enables the system to detect and prevent operational errors, validate switching conditions, and ensure safe operation. The feedback loop allows the control device to adapt to actual system conditions, reducing the risk of errors while maintaining user-friendly operation.
3Ease of manufacture
If return springs and mechanical reset mechanisms are used, then automatic return to zero position is achieved, but assembly costs and maintenance requirements increase
Solution Approach 1:
The patent replaces mechanical reset mechanisms with electrical or software-based reset functions. Instead of using return springs that require mechanical assembly and periodic maintenance, the system uses electrical signals or software commands to reset the switching state. This eliminates the need for mechanical reset components, reducing assembly costs and maintenance requirements while simplifying the overall device structure.
4Adaptability or versatility
If electronic operating systems with cursor-based navigation are used, then parameter changes are possible, but the system is not suitable for controlling machines with motion drives
Solution Approach 1:
The patent creates a control device that integrates multiple functions: it can display and change parameters like general electronic systems, but also directly control motion drives through integrated switching elements and sensors. The control device serves both as a parameter adjustment interface and as a direct control mechanism for machine axes, eliminating the need for separate control systems and improving ease of operation while maintaining versatility.
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 solution enhances the operability and safety of industrial machines by providing intuitive, error-reduced manual control of machine axes with flexible haptic feedback and reduced mechanical complexity, minimizing the risk of damage and operational errors while maintaining low assembly and maintenance costs.
Implementation Method 1
the actuating element or its axis of rotation is in mechanical interaction with a controlled variable rotational resistance generation means
Data Source
Figure 1
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AI summary
The invention relates to a control device (2, 2') for industrial machines with controlled motion drives (13) for machine components. In this case, a man-machine interface (6) is provided with at least one control element (16) for manually influencing or specifying adjustment movements of at least one of the machine components. At least one control element (16) is designed as a rotary actuator control element (17) having an actuating member (18) that is rotatably mounted about an axis of rotation (22). The actuating member (18) or its axis of rotation (22) is in mechanical interaction with a controlled variable rotational resistance generating means (23). An electronic evaluation and control device (20) is designed for the variable adjustment of rotational resistances of the rotational resistance generating means (23). The evaluation and control device (20) is designed for providing at least one toggle switch operating mode, in which the rotational resistance generating means (23) is controllable by the evaluation and control device (20) in such a way that the rotational resistance generating means (23) builds up or generates a braking or blocking torque after covering a predefined rotation angle of the actuating member (18), which inhibits, inhibits in a reinforcing manner or prevents a further rotatability of the actuating member (18).