FIELD OF THE INVENTION
[0001] The present invention relates to a rotary variable resistor which is operable by
repeatedly rotating the operation shaft thereof and used for various electronic apparatuses,
and, an output regulator using the same.
BACKGROUND OF THE INVENTION
[0002] A conventional rotary variable resistor which is operable by repeatedly rotating
the operation shaft thereof is described hereinafter on reference to Fig. 6, Fig.
7 and Fig. 8.
[0003] In Fig. 6, on the inner surface of the bottom of a case 1 made of insulating resin,
a resistor board 2 is fixed by insertion-molding. At the center of the resistor board
2, a round hole 821 is formed in such a manner as to be concentric with a round hole
811 formed at the center of the bottom of the case 1.
[0004] In Fig. 7, which is a schematic diagram showing the main portion of the conventional
rotary variable resistor, the resistor board 2 is formed as follows.
[0005] On the upper surface of an insulating substrate 822, a horseshoe-shaped first resistive
film 3 is formed. At the outer side of the first resistive film 3, a horseshoe-shaped
first current collecting member 4 formed with argentic material by printing is disposed
in such a manner as to be concentric with the central round hole 821 and to face the
opening thereof toward the same direction with the facing direction of the opening
of the first resistive film 3. From the respective ends of the first resistive film
3, lead members 5 extend outward and are respectively connected to terminals 7 (71,
72) by caulking. Also, from one end of the first current collecting member 4, a lead
member 6 extends outward and is connected to a terminal 8 by caulking.
[0006] Also, an annular second current collecting member 9 is formed by printing at the
innermost position in such a manner as to be concentric with the round hole 821. From
the second current collecting member 9, a lead member 10 extends outward and is connected
to a terminal 11 by caulking.
[0007] Also, between the first resistive film 3 and the second current collecting member
9, a pair of circular arc shaped conductive members 12 formed with argentic material
by printing are disposed between the opening side portion of the first resistive film
3 and the second current collecting member 9 in such a manner as to be concentric
with the round hole 821. On the conductive members 12 and the lead member 10 of the
second current collecting member 9, insulating resist 13 is applied in such a manner
as to cover a larger angular range than the angular opening of the first resistive
film 3. In this case, the respective end portions (i.e., upper end portions in Fig.7)
of the conductive members 12 are left without applying the resist 13. On the resist
13, a horseshoe-shaped second resistive film 14 is formed by printing in such a manner
as to cover a larger angular range than the angular opening of the first resistive
film 3. In this case, the respective ends of the second resistive film 14 is electrically
connected to the respective end portions (i.e., upper end portions in Fig. 7) of the
conductive members 12, where the insulating resist 13 is not applied. From the respective
conductive members 12, lead members 15 extend outward and are respectively connected
to terminals 16 (161, 162) by caulking.
[0008] In Fig. 6, an operation shaft 17 made of insulating resin is disposed in such a manner
as to protrude outward through the hole 181 of a bearing member 18 which is fixed
to the case 1 with a metal cover 25. A round protrusion 171 formed at the center of
the bottom of the operation shaft 17 engages with the respective round holes (811,
821) of the case 1 and the resistor board 2, whereby the shaft 17 is supported in
such a manner as to be repeatedly rotatable.
[0009] To the operation shaft 17, a first brush 21 and a second brush 22 respectively made
of elastic metal plates are disposed in such a manner as to be electrically isolated
each other. The contact portions 19 (191, 192) of the first brush 21 and the contact
portions 20 (201, 202) of the second brush 22 are disposed in such a manner as to
be on a straight line extended along the radius of the operation shaft 17 (the radius
starts from the rotation axis of the operation shaft).
[0010] As shown in Fig. 7, the contact portion 191 of the first brush 21 elastically contacts
to the first resistive film 3, and the contact portion 192 of the same elastically
contacts to the first current collecting member 4. The first brushes 21, the first
resistive film 3 and the first current collecting member 4 form a first resistor unit
23.
[0011] The contact portion 201 of the second brush 22 elastically contacts to the second
resistive film 14, and the contact portion 202 of the same elastically contacts to
the second current collecting member 9. The second brush 22, the second resistive
film 14 and the second current collecting member 9 form a second resistor unit 24.
[0012] In the rotary variable resistor having the above structure, the contact portions
19 (191, 192) of the first brush 21 and the contact portions 20 (201, 202) of the
second brush 22 slide on the respective printed patterns elastically contacting to
these patterns, whereby output voltage at a predetermined rotational angle of the
operation shaft 17 is obtained either from the first resistor unit 23 though the terminals
71 and 8 for instance, or from the second resistor unit 24 through the terminals 162
and 11 for instance.
[0013] As shown in Fig. 8, effective output voltage is obtained alternately from the first
resistor unit 23 and the second resistor unit 24 according to the rotation of the
operation shaft 17. In this case, the beginning and the ending portions of the effective
output voltage of the respective resistor units (23, 24) overlap (i.e., effective
voltage is obtainable from both).
[0014] In the practical use of the rotary variable resistor having the above structure,
either of the effective output voltage is selected on the overlapping portions based
on the judgment of a computer or the like, whereby effective output voltage is successively
obtained either from the first resistor unit 23 or from the second resistor unit 24.
[0015] However, in the above conventional structure, the second resistive film 14 is formed
on resist 13 applied on the predetermined portions of the conductive member 12 and
the lead member 10 of the second current collecting member 9, also, for the input
and the output to and from the first and the second resistor units (23, 24), six terminals
(71, 72, 8, 11, 161 and 162) are needed. Therefore, the pattern structure is complicated,
which requires many and complicated production processes.
SUMMARY OF THE INVENTION
[0016] The object of the present invention is to address the above conventional problems
and to provide a rotary variable resistor which is operable by repeatedly rotating
the operation shaft thereof and has simple pattern structure on the resistor board
thereof, also has a few terminals. It is a further object of the present invention
to provide an output regulator which uses the above rotary variable resistor.
[0017] For realizing the above object, the rotary variable resistor of the present invention
comprises:
(a) a resistive film disposed on an insulating substrate,
(b) a current collecting conductive member disposed in such a manner as to be concentric
with the resistive film, and, to be spatially isolated from the resistive film and
the lead members thereof,
(c) a circular arc shaped auxiliary conductive member formed in such a manner as to
be concentric with the resistive film, and, to be spatially isolated from the resistive
film, the current collecting conductive member and the lead members of these patterns,
also to cover a larger angular range than the angular opening of the resistive film,
(d) a first brush made of an elastic metal plate, and fixed to an operation shaft
which is repeatedly rotatable, also having a first contact portions which respectively
elastically contact to the resistive film and to the current collecting conductive
member, wherein the first brush forms a first resistor unit together with the resistive
film and the current collecting conductive member; and
(e) a second brush made of an elastic metal plate, and fixed to the operation shaft
in such a manner as to be electrically isolated from the first brush, also having
a second contact portions which respectively elastically contact to the resistive
film and to the auxiliary conductive member in the rotational angular range of the
operation shaft, in which a predetermined output voltage is unobtainable from the
first resistor unit, wherein the second brush forms a second resistor unit together
with the resistive film and the auxiliary conductive member.
[0018] In the rotary variable resistor of the present invention having the above structure,
one resistive film is commonly used for the first and the second resistor units, and
the multilayer pattern as in the conventional structure is eliminated, whereby the
pattern structure of the resistor board is simplified, also the number of terminals
is decreased, accordingly the production process is simplified and the cost is also
decreased.
[0019] For realizing the further object of the present invention, the output regulator of
the present invention comprises:
(a) the above rotary variable resistor,
(b) a power source unit for applying a predetermined voltage to the rotary variable
resistor,
(c) an analog-to-digital converter having an input port through which the output voltage
of the first resistor unit of the rotary variable resistor, the output voltage of
the second resistor unit of the same and the voltage applied to the rotary variable
resistor are respectively input,
(d) a detecting unit for detecting the output voltage value of the second resistor
unit,
(e) a comparing unit for comparing the output voltage value of the second resistor
unit, which is detected by the detecting unit, with the voltage applied to the rotary
variable resistor,
(f) an arithmetic processing unit for outputting an output code corresponding to the
output voltage value of the first resistor unit when the comparing unit judges the
output voltage value of the first resistor unit to be effective as a result of the
comparison, and for outputting an output code corresponding to the output voltage
value of the second resistor unit or a predetermined output code stored in advance
when the comparing unit judges the output voltage value of the first resistor unit
to be ineffective as a result of the comparison, and
(g) an output port for outputting the output codes.
[0020] In the rotary variable resistor of the present invention having the above structure,
successive proper output codes are obtainable in the repeated rotation of the operation
shaft by performing simple signal processing with a microcomputer or the like based
on the output voltage value of the first or the second resistor unit of the rotary
variable resistor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021]
Fig. 1 is a schematic diagram showing the main portions (i.e., the upper side of the
resistor board) of a rotary variable resistor in a first exemplary embodiment of the
present invention,
Fig. 2 shows the characteristics of the output voltage of the rotary variable resistor
in the same,
Fig. 3 is a schematic diagram showing the main portions (i.e., the upper side of the
resistor board) of a rotary variable resistor in a second exemplary embodiment of
the present invention,
Fig. 4 is a schematic diagram showing an output regulator in a third exemplary embodiment
of the present invention,
Fig. 5 is a flow chart showing the signal processing of the output regulator in the
same,
Fig. 6 is a cross sectional view of a conventional rotary variable resistor.
Fig. 7 is a schematic diagram showing the main portions (i.e., the upper side of the
resistor board) of the same, and
Fig. 8 shows the characteristics of the output voltage of the same.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Hereinafter the exemplary embodiments of the present invention are described on reference
to illustrations.
First Exemplary Embodiment
[0023] Fig. 1 is a schematic diagram showing the main portions of a rotary variable resistor
in a first exemplary embodiment of the present invention, and Fig. 2 shows the characteristics
of the output voltage of the rotary variable resistor in the same.
[0024] As shown in Fig. 1, the rotary variable resistor of this exemplary embodiment is
different from the conventional rotary variable resistor in the pattern structure,
the terminal structure and the elastically contacting positions of a first brush 31
and a second brush 32, which are respectively disposed on a resistor board 30. Regarding
the other components of the rotary variable resistor of this exemplary embodiment,
structure and functions are same with the conventional rotary variable resistor. Therefore
the illustrations and the descriptions on these components are omitted.
[0025] In Fig. 1, the resistor board 30 of this exemplary embodiment is formed as follows.
That is, a horseshoe-shaped resistive film 33 is formed by printing on an insulating
substrate 302 which has a round hole 301 at the center thereof. From the respective
ends of the resistive film 33, lead members 34 made of argentic material extend outward
and are respectively connected to terminals 35 (351, 352).
[0026] Also, at the inner side of the resistive film 33, an annular current collecting conductive
member 36 formed with argentic material by printing is disposed in such a manner as
to be concentric with the resistive film 33 and to be spatially isolated from the
resistive film 33 and the lead members 34. From the current collecting conductive
member 36, a lead member 37 extends outward and is connected to a terminal 38.
[0027] Also, at the outer side of the resistive film 33, a circular arc shaped auxiliary
conductive member 39 formed with argentic material by printing is disposed in such
a manner as to be concentric with the resistive film 33 and the current collecting
conductive member 36, and, to be spatially isolated from the resistive film 33, the
current collecting conductive member 36 and the lead members (34, 37), also to cover
a larger angular range than the angular opening of the resistive film 33. From the
auxiliary conductive member 39, a lead member 40 extends outward and is connected
to a terminal 41.
[0028] Also, a first brush 31 and a second brush 32, which respectively elastically contact
to the respective patterns formed on the resistor board 30, are fixed to an operation
shaft (not illustrated), which is repeatedly rotatable, in such a manner as to be
electrically isolated each other.
[0029] Also, as shown in Fig. 1, the first brush 31 has contact portions 42 (421, 422) which
respectively slide on the resistive film 33 and on the current collecting conductive
member 36 elastically contacting to these patterns (33, 36). The first brush 31, the
resistive film 33 and the current collecting conductive member 36 form a first resistor
unit 43.
[0030] Also, the second brush 32 has contact portions 44 (441, 442) which respectively slide
on the resistive film 33 and on the auxiliary conductive member 39 elastically contacting
to these patterns (33, 39) in an angular range in which predetermined output voltage
is unobtainable from the first resistor unit 43. The second brush 32, the resistive
film 33 and the auxiliary conductive member 39 form a second resistor unit 45.
[0031] In the rotary variable resistor having the above structure, the contact portions
42 of the first brush 31 and the contact portions 44 of the second brush 32 respectively
slide on the respective patterns formed on the resistor board 30 elastically contacting
to these patterns according to the rotation of the operation shaft (not illustrated),
and, output voltage at a predetermined rotational angle is obtained either from the
first resistor unit 43 or from the second resistor unit 45 through the respective
terminals (35, 38, 41) as in the case of the conventional rotary variable resistor.
However, in this exemplary embodiment, different from the conventional structure,
both first brush 31 and second brush 32 elastically contact to the one resistive film
33, whereby the number of the terminals can be decreased to four (i.e., terminals
351, 352, 38 and 41), and, for instance, the output voltage of the first resistor
unit 43 is obtained through the terminals 351 and 38, and, the output voltage of the
second resistor unit 45 is obtained through the terminals 351 and 41.
[0032] In Fig. 2, the effective output voltage of the first resistor unit 43 is obtained
in an angular range where the horseshoe-shaped resistive film 33 is formed, and the
effective output voltage of the second resistor unit 45 is obtained in the other angular
range. In this case, the beginning and the ending portions of the respective effective
output voltage of the first and the second resistor units (43, 45) overlap (i.e.,
effective output voltage is obtainable from both).
[0033] As described in the above, in the rotary variable resistor in this exemplary embodiment,
the output voltage of the first and the second resistor units (43, 45) is obtained
by elastically contacting both first and second brushes (31, 32) to the one resistive
film 33, whereby the pattern structure of the resistor board 30 is simplified, accordingly
the process for forming the pattern is simplified, also the number of the terminals
is decreased. Thus a rotary variable resistor, with which desired output voltage is
successively obtained by repeatedly rotating the operation shaft, can be realized
with less production processes effectively.
[0034] In the above description, the auxiliary conductive member 39 is disposed at the outermost
position on the resistor board 30. However, the same effect can be obtained by disposing
the auxiliary conductive member 39 between the resistive film 33 and the current collecting
conductive member 36. Also, by forming the current collecting member 36 to have a
horseshoe-shape having an angular opening corresponding to the angular opening of
the resistive film 33, instead of the annular shape as in the above description, the
same effect can be obtained. Also, by disposing the resistive film, the current collecting
conductive member and the auxiliary conductive member in the other order than the
above description, the same effect can be obtained if these patterns are disposed
in such a manner as to be spatially isolated each other.
Second Exemplary Embodiment
[0035] Fig. 3 is a schematic diagram showing the main portion (i.e. the upper side of the
resistor board) of a rotary variable resistor in a second exemplary embodiment.
[0036] In this exemplary embodiment, the pattern structure of the resistor board 50 is different
from that of the first exemplary embodiment. That is, a horseshoe-shaped current collecting
conductive member 51 is additionally formed with argentic material by printing between
the horseshoe-shaped resistive film 33 and the annular current collecting conductive
member 36 in such a manner as to be spatially isolated from these patterns (33, 36).
Also, different from the first exemplary embodiment, a second brush 52 having three
contact portions (521, 522, 523) is disposed. The three contact portions (521, 522,
523) respectively slide on the resistive film 33, the auxiliary conductive member
39 and the current collecting conductive member 51 elastically contacting to these
patterns (33, 39, 51). As a result, a third resistor unit 53 comprising the second
brush 52, the resistive film 33 and the current collecting conductive member 51 is
formed in addition to the first and the second resistor units (43, 45).
[0037] In the rotary variable resistor of this exemplary embodiment having the above structure,
effective output voltage having the same voltage value is obtainable from both second
and third resistor units (45, 53) in a rotational angular range in which effective
output voltage is unobtainable from the first resistor unit 43. Therefore, the output
voltage of either the second resistor unit 45 or the third resistor unit 53 can be
selectively used according to the necessity.
Third Exemplary Embodiment
[0038] Fig. 4 is a schematic diagram showing an output regulator in a third exemplary embodiment
of the present invention, and Fig. 5 is a flow chart showing signal processing of
the output regulator in the same.
[0039] First, the structure of the output regulator which uses the rotary variable resistor
of the first exemplary embodiment is described on reference to Fig. 4.
[0040] As shown in Fig. 4, a minus terminal of a power source unit 60 is connected to the
terminal 351 of the resistive film 33 of the rotary variable resistor, and a plus
terminal of the power source unit 60 is connected to the other terminal 352 of the
resistive film 33, whereby a predetermined voltage is applied to the resistive film
33 from the power source 60.
[0041] The output voltage of the first resistor unit 43, which is obtained through the terminal
351 of the resistive film 33 and the terminal 38 of the current collecting conductive
member 36, the output voltage of the second resistor unit 45, which is obtained through
the terminal 351 of the resistive film 33 and the terminal 41 of the auxiliary conductive
member 39, and, the output voltage of the power source 60 (i.e., voltage applied to
the rotary variable resistor) are input to the input port 63 of the analog-to-digital
converting unit 62 of the microcomputer 61.
[0042] The analog-to-digital converting unit 62 converts the voltage signals (i.e., analog
voltage signals) received through the input port 63 to digital voltage signals and
sends the digital voltage signals to a detecting unit 64.
[0043] Then the detecting unit 64 detects the value of the digital voltage signal of the
second resistor unit 45. Then the comparing unit 65 compares the value of the second
resistor unit 45 with the voltage value applied to the rotary variable resistor.
[0044] The reason of the comparison is that, as described in the first exemplary embodiment,
in the rotary variable resistor of the present invention, the first and the second
resistor units (43, 45) respectively have operational angular ranges for outputting
effective output voltage, and, the beginning and the ending portions of the effective
output voltage of the first and the second resistor units (43, 45) overlap (i.e.,
effective voltage is obtainable from both). Therefore, in the angular ranges in which
the effective voltage is obtainable from both, judgment based on the comparison is
required for selecting either of the output voltage.
[0045] Next, the process for selecting the effective voltage is described on reference to
Fig. 5. In Fig. 5, the comparing unit 65 judges the output voltage of the first resistor
unit 43 to be effective when the output voltage of the second resistor unit 45 is
lower than 90% of the voltage applied to the rotary variable resistor, and, to be
ineffective when the output voltage of the second resistor unit 45 is equal or higher
than 90% of the voltage applied to the rotary variable resistor.
[0046] When the comparing unit 65 judges the output voltage value of the first resistor
unit 43 to be effective, an arithmetic processing unit 66 reads out an output code
corresponding to the output voltage value of the first resistor unit 43 from a setting
storing unit 67, and sends the code to an output port 68.
[0047] On the other hand, when the comparing member 65 judges the output voltage value of
the first resistor unit 43 to be ineffective, the arithmetic processing unit 66 reads
out an output code corresponding to the output voltage value of the second resistor
unit 45 or a predetermined code which is stored in advance from the setting storing
unit 67 and send the code to the output port 68.
[0048] In the above description, the judgment of the effectiveness of the output voltage
is performed based on the value of 90% of the voltage applied to the rotary variable
resistor. However, the same effect can be obtained by performing the judgment based
on the other voltage value.
[0049] As described in the above, the output regulator of this exemplary embodiment can
be formed to have simple structure and small size by using the rotary variable resistor
of the present invention having a few terminals and operable by repeatedly rotating
the operation shaft.
[0050] Also when the setting storing unit 67 is a rewritable type, output codes are changeable
according to purpose by changing the setting of codes stored in advance.
[0051] In the above description, the output voltage value of the second resistor unit 45
is compared with the voltage value applied to the rotary variable resistor. However,
the same effect can be obtained by comparing the output voltage value of the first
resistor unit 43 with the voltage value applied to the rotary variable resistor.
[0052] As described in the above, in the rotary variable resistor of the present invention,
one resistive film is used for both first and second resistor units, and, the multilayer
pattern as in the conventional structure is eliminated, also the number of terminals
is decreased, whereby the pattern of the resistor board is simplified. Thus a low
cost rotary variable resistor is obtained with simplified production process effectively.
[0053] Also, by using the rotary variable resistor of the present invention, an output regulator,
with which successive proper output codes are obtainable in the repeated rotation
of the operation shaft by performing simple signal processing with a microcomputer
or the like based on the output voltage value of the first or the second resistor
unit, can be realized.
[0054] Also, in the output regulator, output codes are changeable according to necessity
by changing the setting of codes stored in advance.