Rotary Haptic Control for Industrial Motion Drive Safety
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Solution Overview
Problem
Existing control systems for industrial machines with motion drives are not adequately operable or programmable, limiting their effective control and safety in industrial settings, as they rely on visual indicators and lack intuitive haptic feedback.
Innovation Solution
A control device with a rotary actuating element connected to a variable rotational resistance generating means, which provides haptic feedback to the operator based on machine states or events, allowing for improved manual control and safety by inhibiting or increasing rotational mobility as necessary, thus preventing errors and hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If visual indicators and conventional control elements are used, then the control system can display machine states, but the operator cannot intuitively perceive machine states or events without visual attention
Solution Approach 1:
The control system segments information transmission channels by separating visual display functions from tactile feedback functions. The rotary control element provides dedicated tactile feedback for machine states, while visual displays handle other information, allowing operators to perceive critical machine states through touch without visual attention.
Solution Approach 2:
The rotary control element acts as an intermediary between the machine control system and the operator. It translates machine states into haptic feedback signals that the operator can perceive through touch, serving as a mediator that conveys information without requiring visual attention.
2Ease of operation
If the rotary control element allows free rotation, then the operator can freely adjust machine components, but the operator cannot perceive machine states or potential hazards through tactile feedback
Solution Approach 1:
The system implements tactile feedback through the rotary control element by varying rotational resistance based on machine states. When approaching prohibited zones or critical states, the resistance changes to alert the operator, providing continuous feedback that maintains both operational freedom and safety.
Solution Approach 2:
The control system applies preliminary anti-action by increasing rotational resistance before the machine component reaches a prohibited zone or hazardous state. This preemptive resistance change warns the operator in advance, preventing errors before they occur rather than reacting after the fact.
3Reliability
If rotational resistance is constantly high, then the operator receives strong haptic feedback, but the operator cannot freely adjust machine components
Solution Approach 1:
The rotational resistance of the control element is made dynamic rather than static. The resistance varies continuously based on machine states, being low during normal operation to allow free adjustment and high when approaching hazardous states to provide strong haptic feedback. This dynamic adaptation resolves the contradiction between feedback clarity and operational freedom.
Solution Approach 2:
The system changes the physical parameter of rotational resistance based on operating conditions. By modulating this parameter in response to machine states, the system provides strong haptic feedback only when necessary while maintaining ease of operation during normal conditions, eliminating the need for constantly high resistance.
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
Enhances the operability and safety of industrial machines by providing clear, haptic feedback that allows operators to focus on machine components without visual indicators, reducing the risk of damage or hazards and enabling rapid, error-preventive operation.
Implementation Method 1
the rotational resistance generating means can be driven by an analysis and control device, and that the rotational resistance generating means and the analysis and control device are equipped to inhibit the rotational mobility of the actuating element or to subject it to an increased rotational resistance that is haptically perceptible by an operator
Data Source
AI summary
A control device for industrial machines having controlled motion drives for machine components has at least one control element configured to manually influence or specify adjustment movements of at least one machine component and is implemented as a rotary control element with a continuously rotatable actuating element connected in terms of motion to a rotational resistance generator that is variable under control or the actuating element can be connected in terms of motion thereto. The rotational resistance generator is drivable by an analysis and control device. The analysis and control device and the rotational resistance generator in this case are equipped to inhibit the rotational mobility of the actuating element, or to subject it to an increased rotational resistance haptically perceptible by an operator, as a function of machine states or events known to or sensed by the control device. In addition, a corresponding control method is specified.