Sealed Multi-Axis Control Lever With PCB and Switch Integration
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Solution Overview
Problem
Multi-axis control levers face sealing issues due to their ergonomic design, which complicates the integration of sealed switches and rollers, and the use of printed circuit boards, leading to problems in non-cabin construction equipment and tractors, where users struggle to determine switch activation and CAN communication status, and require extensive wire harnesses.
Innovation Solution
A control lever design featuring a safety body with a filler that seals the printed circuit board and switches, a warning area with light sources for user feedback, and a connecting element allowing asymmetric mounting, which improves sealing and reduces cable complexity by integrating the CAN communication system into a single line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple switches and rollers are provided on the control lever, then the control functionality is improved, but the sealing problem worsens due to the ergonomic structure of the handle section
Solution Approach 1:
The control lever is divided into a handle section and a base section, with the handle section further segmented to accommodate multiple switches and rollers on its outer surface. This segmentation allows each control element to be positioned ergonomically while maintaining the overall sealing integrity through the separate base section housing
Solution Approach 2:
The switches and rollers are integrated into the handle section structure, which itself is nested within the base section. The handle section acts as a container for the control elements, allowing them to be housed together while maintaining sealing through the base section's protective enclosure
2Ease of operation
If printed circuit boards are applied to the inner surface of the control lever, then the interaction between switches and control system is improved, but the sealing problem worsens due to the opened upper surface of the PCB
Solution Approach 1:
The printed circuit boards are extracted from the handle section and relocated to the base section. This extraction allows the handle section to maintain its ergonomic shape with all control elements on the outer surface, while the base section provides a sealed environment for the PCBs, resolving the sealing issue caused by exposed PCB surfaces
3Adaptability or versatility
If a great number of switches and rollers are provided, then the control capabilities are improved, but the wire harness complexity increases substantially
Solution Approach 1:
Multiple control signals from switches and rollers are merged into a single printed circuit board system in the base section. The PCBs integrate multiple signal paths and communication protocols (including CAN communication) into unified circuitry, reducing the need for separate cables for each control element and substantially simplifying the wire harness
4Ease of operation
If the control lever is designed ergonomically with inclined and curved surfaces, then the user comfort is improved, but the manufacturing complexity increases due to distinct molding requirements
Solution Approach 1:
The control lever is segmented into the handle section and base section as separate moldable components. The handle section can be molded with ergonomic inclined and curved surfaces independently, while the base section is molded separately to house the PCBs and control elements. This segmentation reduces manufacturing complexity compared to molding the entire assembly as one complex piece
Data Source
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AI summary
The present invention relates to a control lever (1) enabling a multi-axis control by being fitted on a control lever base (2) and comprising a front handle section (6) suitable to be hold by an user and capable of moving axially, a rear handle section (7) coupled with the front handle section (6); a plurality of switches (15) suitable to be controlled by the user and used as control elements, and at least one printed circuit board (18). Said control lever further comprises a front surface (30) arranged at the upper portion of the said front section (6) and a plurality of switch holes (31) provided on the front surface (30) and receiving a plurality of switches (15); at least one warning area (16), at the rear side of which there is located at least one light source (19); at least one printed circuit board housing (17a) in which at least one printed circuit board (18) is disposed, a wall (17b) extending into the control lever (1) integral with the said front surface (30), and a safety body (14) having a filler (20) which, when in use, at least party covers its inner side in a sealing manner.