Technical Field of Invention
[0001] The present invention relates to an industrial control lever and more particularly
to a reliable control lever with increased precision suitable to be used in industry,
agriculture, construction equipment, marine vessels, aviation and similar fields of
operation.
State of the Art
[0002] Currently, control levers, also called as joysticks, are often used in industrial
field in order to control movement in a number of axes.
[0003] Different types and kinds of the control levers are manufactured, among which
US5068499 and
US4559420 may be exemplified. In the control levers disclosed in these patent documents, angle
sensors must be arranged perpendicular to the control lever and do not allow a direct
detection from the control lever, thereby requiring interposition of a second insert.
This may cause a reduction in precision. Also, separate sealing measures must be taken
for the two sensors used in such structures, and suitable magnetic members must also
be utilized corresponding to the present sensors. Additionally, due to the fact that
at least two sensor projections will emerge in the control lever, it would be hard
to insert it into the device.
[0004] In prior art, control levers are used wherein a first axle part is connected to the
body and a second axle part is connected on the first axle. An example of such control
levers is disclosed in
US6462731 (B1). In these systems, a magnetic member should exactly face to the integrated circuit
(IC) focus, and since the IC must exactly be positioned on the rotation axis and is
located at the center, the first axle is formed as a convex and the second axle is
formed as a concave so that a space is created therebetween. Further, a main board
must be disposed at the lower section, and by the very nature of the system, those
parts forming the first and second axles project outward. When it is rotated, an excess
space must be created at the lower section, which restricts insertion of a single
board close to the center of rotation. It is necessary for the system to retain the
arms of the torsion springs utilized at the upper side, and in case said torsion springs
are moved to the lower side, the space provided therein must be further increased.
Superimposition of the spring arms cannot ensure the feeling that the spring control
lever is retained where it is left, thereby complicating production of friction detection
systems.
[0005] Another control lever of the prior art is ball-joint control lever systems. International
patent application no.
WO00/39654 may be given as an example for such control levers actuated with ball joints. Also
in such systems, the control lever is spherically connected to the body, and it would
be hard to eliminate the space which is thus created in the ball joints. Therefore,
there is a need to provide a durable control lever with increased precision and increased
security.
Objects of the Invention
[0006] Principal object of the present invention is to provide a compact, reliable and precise
control lever wherein a number of components are eliminated through use of a single
printed circuit board.
[0007] Another object of the present invention is to provide a control lever with increased
security achieved by means of independent springs.
[0008] Another object of the present invention is to provide a control lever which prevents
an undesired positioning of the spring and maloperation by comprising projections
that retain the torsion springs at the center, so that it has an increased security.
[0009] Another object of the present invention is to provide a control lever wherein a single
magnetic member is sufficient.
[0010] Another object of the present invention is to provide a control lever wherein use
of single printed circuit board is sufficient.
[0011] Another object of the present invention is to provide a control lever which provides
a direct connector outlet for the user so that he will not need a cable.
[0012] Another object of the present invention is to provide a control lever wherein undesired
positioning of the springs and maloperation is prevented by means of projections that
retain the torsion springs at the center.
[0013] Another object of the present invention is to provide a control lever which prevents
unauthorized persons to fill all components of the control lever assembly with resin
so as to open the components.
[0014] Another object of the present invention is to provide a control lever which ensures
effective friction due to the fact that the bottom of the pressure plate is made of
TPE material and the upper part thereof is made of a more rigid material.
Summary of the Invention
[0015] The present invention relates to a control lever for a heavy equipment, comprising
a body; a printed circuit board assembly having a printed circuit board having thereon
at least one sensor; a lever holder which has a central hole, through which a control
arm is at least party engaged, wherein the control arm is rotatable about its longitudinal
axis, and which has at least one cocking spring at each end, a magnetic member fastened
to an end of the said control lever and suitable to interact with the sensor provided
on the printed circuit board. Said control lever comprises a lever supporting member
in the form of "C", which is arranged such that its opened section faces to the printed
circuit board and which is suitable to rotate about its longitudinal axis, wherein
the control arm is engaged into a slot provided at the center thereof, and at least
one cocking spring is arranged at its each end.
Brief Description of the Figures
[0016] The figures of the subject matter control lever, whose brief explanations are herewith
provided, are solely intended for providing a better understanding of the present
invention and are as such not intended to define the scope of protection or the context
in which said scope is to be interpreted in the absence of the description.
Figure 1 is an exploded view of the control lever according to the present invention;
Figure 2 is a perspective view of the control lever body, a stopper plate and a bellow
according to the present invention.
Figure 3 is a perspective view of friction plates used in the control lever according
to the present invention.
Figure 4 is a perspective view of the control lever according to the present invention,
with printed circuit card and external protection shield.
Figure 5 is a cross-sectional view of the control lever according to the present invention.
Figure 6 is a partial exploded view of the control lever according to the present
invention.
Figure 7 is a perspective view of a printed circuit board and housing of the control
lever according to the present invention.
Figure 8 is a perspective view showing the connection region of the control lever
according to the present invention.
Figure 9 is a partial cross-sectional view showing the connection of the control lever
according to the present invention with the protection sheet.
Figure 10 is a perspective view of the printed circuit board of the control lever
according to the present invention.
Figure 11a is a longitudinal cross-sectional front view of the control lever according
to the present invention.
Figure 11b is a side sectional view of the control lever according to the present
invention.
Figure 11c is a longitudinal cross-sectional rear view of the control lever according
to the present invention.
Figure 12a is a schematic drawing illustrating the effect of the desired distance
between the sensor and the magnetic member due to the control lever according to the
present invention.
Figure 12b is a schematic drawing showing the magnetic effect caused by the control
lever according to the present invention.
Detailed Description of the Invention
[0017] The invention will now be described in detail with reference to the accompanying
drawings, wherein reference numerals assigned to the parts therein are listed as follows;
- 40.
- Control lever
- 1.
- Control arm
- 1a.
- Lower portion
- 1b.
- Connection hole
- 2, 9, 12
- Bushing
- 3.
- Bushing connecting element
- 4.
- Lever holder
- 4a.
- Bushing hole
- 4b.
- Central hole
- 4d.
- Pin hole
- 4e.
- Lateral projection
- 4f.
- Montage area
- 4g.
- Spring alignment projection
- 4j.
- Detent recess
- 6.
- Segment
- 7.
- Magnetic member
- 8.
- Pin
- 9.
- Bushing
- 10.
- Cocking spring
- 10a.
- Spring arm
- 11.
- Lever supporting member
- 11a.
- Slot
- 11c.
- Lever supporting projection
- 11d.
- Spring projection
- 11e.
- Inner section
- 11f.
- Alignment projection
- 11g.
- Spring alignment projection
- 12.
- Bushing
- 13.
- Body
- 13a.
- Accommodation space
- 13b, 13c
- Recess
- 13d.
- Spring setting projection
- 13e.
- Rectangular recess
- 14.
- Lower body member
- 14a.
- Lower body cavity
- 14b, 14c
- Cylindrical recess
- 14d.
- Spring alignment projection
- 15.
- Connection area
- 16.
- Stopper plate
- 16a.
- Connecting plate
- 16c.
- Connecting member headspace
- 16.
- Spring space
- 17.
- Connecting bolt
- 18.
- Resin filler
- 19.
- Friction plate
- 19a.
- Friction plate upper section
- 19c.
- Rubber-based material
- 19b.
- Friction plate lower section
- 19d.
- Engagement surface
- 20.
- Pressure spring
- 21.
- Printed circuit board
- 21a.
- Printed circuit board pin
- 22.
- Printed circuit board housing
- 22a.
- Connection hole
- 22b.
- Hole
- 22c.
- Cut hole
- 22d.
- Connector outlet
- 22e.
- Connector inlet
- 22f.
- Resin space
- 23.
- Contact element
- 24.
- Elastic member
- 25.
- Printed circuit board assembly
- 25a.
- Resin filler
- 26.
- Mechanical assembly
- 27.
- Bolt
- 29.
- External protection sheet
- 30.
- Bellow
- 41.
- Detent plate
- P
- Pivot point
- α
- Rotation angle
[0018] The control lever (40) for a heavy equipment according to the present invention is
formed to be used in industrial filed, agriculture, marine vessels, aviation and similar
fields of operation. Said control lever (40) mainly comprises at least one body (13),
a printed circuit board (21) with a HAII IC (Hall-effect sensor integrated circuit)
which is preferably disposed at the center of the body (13) in a horizontal manner,
a lever holder (4) fastened to the said body (13) so as to move pivotally about an
axis Y, a control arm (1) fastened to the lever holder (4) so as to freely rotate
about an axis X, a magnetic member (7) fastened to the lower surface of the control
lever and facing to the printed circuit board, and a lever supporting member (11)
fastened to the axis X of the control arm (1) such that it can move pivotally. The
lever supporting member (11) of the invention is C-shaped, which is arranged such
that the closed section of C-shaped structure is located at the upper section, and
which has a cavity at the center thereof which is suitable for allowing the control
arm (1) to rotate freely at the axis Y, and which comprises at least two cocking springs
(10) at each axis.
[0019] With reference to figure 1, the control arm (1) is made of a material suitable for
being attracted by a magnet, and it has a recess at a lower section (1a) facing to
a printed circuit board (21) that is located immediately therebelow, in which recess
a suitable magnetic member is received. For the said magnetic member, NdFeB or SmCo
may be selected. There is a connection hole (1b) immediately above the recess, and
in this cylindrical connection hole, a bushing (2) member corresponding to the hole
(1b) is engaged. Disposed at the right and left sides of the bushing (2) member, there
is provided one bushing connecting member (3) which is received in a suitable bushing
hole (4a) in the lever holder (4).
[0020] Again referring to figure 1, there is a hole (4b) at the center of the said lever
holder (4), into which said control arm (1) is seated which is then fitted into the
bushing holes (4a) by means of a bushing connecting member (3). Furthermore, each
bushing (2) member is preferably used together with a suitable segment (6). After
the elongated cylindrical rod-shaped control arm (1) is aligned with the opposite
bushing holes on the lever holder (4), it is engaged through the bushing (2) and bushing
connecting member (3) and into connection hole (1b) and fixed therein by means of
a pin that is preferably made of a metal material. As seen in figure 1, rotation of
the control arm (1) about the axis X extending along the longitudinal axis of the
lever holder is ensured by a central hole (4b) formed in the lever holder.
[0021] Referring to figure 1, there is a hollow and preferably circular pin hole (4d) which
is provided in the lever holder (4) in order to allow the lever holder (4) to rotate
about the axis Y, and which is suitable for receiving a pin (8). After the corresponding
pins (8) are engaged into the opposite pin hole (4d), a bushing (9) is inserted onto
an outer projection of each pin (8). The spring arms (10a) of a corresponding cocking
spring (10) are mounted into the montage area (4f) thereon, with a section of a lateral
projection (4e) having a crescent (arc) shape and formed along the longitudinal axis
of the lever holder (4) that is substantially formed in a cylindrical form being typically
closed, which section facing to the printed circuit board (21). Figure 6 shows a corresponding
bushing (9), a cocking spring (10) and the spring arm (10a) mounted on the said control
arm (1) as well as the montage area (4f) where they is mounted. Furthermore, figure
6 also includes recesses (13b and 13c) shaped and formed in a suitable manner.
[0022] With reference to figure 5, a spring alignment projection (4g) supports the bottom
section of the cocking spring (10) where there are no arms, thereby preventing undesired
incidents such as undesired displacement of the spring. As seen in figure 1, the lever
supporting member (11) having a C-shape has, at the center of its upper section, a
slot (11a) which extends transversally. Said control arm (1) is engaged into the slot
(11a) so that the control arm (1) is allowed to rotate about the longitudinal axis
"Y", as seen in figure 6. At the opposite ends of the lever supporting member (11),
there are cylindrical and hollow lever supporting projections (11c), into which bushings
(12) are inserted which allow accommodation therein. Preferably two bushings (12)
are shaped according to these lever supporting projections (11c) and inserted therein.
At the lateral ends of the lever supporting member (11), there are spring projections
(11d) formed as a crescent and preferably positioned at that side facing to the printed
circuit board (21). Again seen in figure 1, two cocking springs (10) are inserted
in the inner surface, i.e. inside (11e), of the opposite spring projections (11d)
and set therein. The spring alignment projections (11f) as shown in figure 5 support
the bottom side of the spring arm that faces outward so that undesired displacement
of the spring is avoided.
[0023] With reference to figure 2, there is stopper plate (16) situated under the bellow
(30) and a body (13) on which said stopper plate (16) is to be disposed. The control
arm (1) is passed through an accommodation space (13a) provided at the center of the
said body (13). With reference to figure 6, a plurality of semicircle recesses (13b,
13c) are present on that side of the body (13) facing to the printed circuit board
(21), and relevant counter bushings (9, 12) are positioned in these semicircle recesses
(13b, 13c). In order words, the spring arms (10a) of the cocking springs (10) are
fixed by preferably eight spring setting projections (13d) based on the outer geometry
of the said bushings (9, 12). Referring to figure 11a, preferably four connecting
members, i.e. nuts are engaged into the said body (13) and they are fitted on the
connection areas (15) by means of injection molding. With reference to figure 4, at
the center of the cylindrically-shaped lower body member (14) there is a lower body
hole (14a), and at its upper side facing to the attachment area, there are cylindrical
recesses (14b, 14c), into which counter bushings (9, 12) are positioned. The spring
alignment projection (14d) supports the bottom side of the spring where there are
no arms and prevents undesired displacement of the spring. The connecting plate (16a)
of the stopper plate (16) is inserted into the rectangular recess (13e) situated at
the handle side of the said body (13) and is fixed by means of suitable connecting
bolts (17) corresponding to the specific connection areas (15). The bolt headspaces
(16c) create a volume for resin filler (18) after montage. Loosening of the bolts
that due to the vibrations that may occur during use is prevented and an intervention
of unauthorized persons to the control lever (40) upon its purchase may be prevented.
[0024] Friction surfaces on the upper section of the arc-shaped lateral projections (4e)
of the lever holder (4) are sandwiched between the pressure springs (20) of the friction
plates (19) and the spring holes (16d) shown in figure 11a. Thus, the user senses
friction and the control lever (40) is retained at the position where it is left by
the user. As seen in figure 3, each friction plate (19) preferably comprises two pressure
springs (20) that extend in vertical direction. At the upper body of the lever holder
(4), there are opposite detent recesses (4j), in which the pressure springs (20) of
the detent plates (41) are compressed between the spring holes (16d) therein. In this
manner, the user is inclined to think that he must exert excess force at the end of
the angular movement. This is mostly preferred in applications where the user desires
to maintain the last movement. In another preferred embodiment of the invention, such
options are available as two free axles, two detent axles, 1 detent axle, 1 free axle
(or vice versa), 1 detent axle, 1 friction axle (or vice versa), 1 friction axle 1
free axle (or vice versa), 2 friction axles.
[0025] Referring to figure 7, the printed circuit board (21) is fixed to the printed circuit
board hole (22) by means of a plurality of screws and through the corresponding connection
holes (22a). The inner side of the printed circuit board hole (22) that faces to the
control lever has a hole for receiving the printed circuit board (21) also called
as PCB. Inside the printed circuit board hole (22), there is a connector outlet (22d)
and a connector inlet (22e).
[0026] There is a hole (22b) on the lower surface of the printed circuit board hole (22)
corresponding to the programming printed circuit board pins (21a) of the printed circuit
board, and an elastic member (24) like a seal is interposed between the hole (22b)
and the printed circuit board (21). With reference to figure 7, there is a cut hole
(22c) on the printed circuit board (21) which enables the EMC contact element (23)
to project outward. Figure 7 shows a printed circuit board assembly (25), inside of
which is preferably coated with resin filler (25a). With this resin filler, a complete
isolation may be achieved during the coating process, except the programming pins.
The printed circuit board assembly (25) is fixed to a mechanical assembly (26) shown
in figure 10 preferably by means of four bolts (27) which are engaged into the connection
areas (15) of the body (13) provided with special nuts. In this way, the entire control
lever (40) is established. With reference to figure 8, it is possible to make programming
based on the mechanical movement via the opened hole (22b). The programming space
is filled with resin filler (25a) so that it is fully sealed, and there is a resin
hole (22f) on the area where the bolts are located which may filled with resin filler.
In this way, loosening of the bolts due to vibration is prevented and an intervention
to the control lever after purchase is avoided.
[0027] Referring to figure 9, EMC contact sheet (23) is compressed between the protection
sheet and the outer surface of the printed circuit board hole (22), while it is being
engaged into the EMC external protection sheet (29), so that it is allowed to have
a permanent contact therewith. When the user connects the EMC external protection
sheet (29) to a ground line, protection is completed. A bellow (30) which is preferably
made of rubber material is placed around the circumference of upper body (13) and
a cut seal (31) is fixed on the lower surface of the EMC external protection sheet
(29), at its lower side, in order to ensure sealing of the control lever inner chamber.
[0028] At either end of the lever holder (4), there are two projections (4e) in the form
of a semi spring like an arc, which are opened at that side facing to the printed
circuit board (21) and have an arc shape in the direction of the axis Y, and said
torsion springs are placed underside of these projections. The lower side (19b) of
the friction plates is preferably circular and the surface (4h) of the lever holder
seats on the bearing area (11h), at the upper side of which, there is at least one
spring. Said spring is pressed against the body (13) or the stopper plate (16) on
the body. The lower portion (19b) of the friction plates is made of rubber-based material
(19c) and the upper portion (19a) thereof is made of rigid thermoplastic or metal
and fixed by means of a clamp-fit surface (19d). Corresponding to those sides of the
cocking springs (10) which have no spring arms (10a), there are two projections (4g)
on the lever holder (4), and two spring alignment projections (11g) are also present
on the movement handle along the axis Y. The printed circuit board assembly (25) is
filled with resin filler until the elements of the printed circuit board (21) are
located thereunder, and at the lower surface of the printed circuit board hole (22),
there is a hole (22b) corresponding to the printed circuit board pins (21a) for programming.
There is an elastic member (24) between this hole (22b) and the printed circuit board
(21).
[0029] The outer surfaces of the corresponding bushing holes (13b, 13c) (14b, 14c) of the
upper body (13) and the lower body member (14) are closed, and the upper body (13),
the lower body member (14) and the printed circuit board body (22) are made of electrical
insulating thermoplastic material. There is an EMC and ESD protection sheet (29) closed
at the lower surface, which has a bowl shape and is elevated up to at least one rotation
axis, and it is ensured that the EMC protection sheet (29) is in contact with the
EMC contact element (23) which is in contact with the printed circuit board (21) and
reaches to the outer surface by means of a cut hole (22c) (without an additional connecting
element or solder). The ESD sheet protects the control lever (40) against the external
effects by means of a grid generated upon a strong magnetic current.
[0030] Hall effect sensors have certain criteria for efficient operation. One of them is
rotation angle (α), which is determined to be 20° in standard, meaning that it cannot
be changed. Another parameter is the distance (h) between the magnetic member and
hall-effect sensor, which distance is also determined in standard based on the flux
density accepted by the said sensor. It is also not possible to change this parameter
in the designing process. Another important distance is the distance (d1, d2) between
the rotation point, i.e. pivot point (P) and the magnetic member (7). This is the
only parameter that may be mechanically intervened. Reducing the distance between
the pivot point (P) and the magnetic member, i.e. the distance d2 as shown in figure
12a increases measurement precision. With the control lever (40) according to the
present invention, the gap between the pivot point (P) and the magnetic member (40)
may be made shorter compared to that in the single board configuration. Referring
to figure 12a, with the invention, the distance (d1) of the pivot point (P) to the
magnetic member (7) may be optimized so as to be shorter. Especially upon a full rotation
of the magnetic member, and also travelled to the extreme points within the ranges
it is allowed to travel, the magnetic angle will not be increased tremendously and
the magnetic flux density will be prevented to reduce further so that the hall-effect
sensor can make a precise measurement. In figure 12b, it is shown that the distance
(d2) between the said pivot point (P) and the magnetic member (7) is kept longer.
In this way, if the distance is long, precision will be lower than that in figure
12a.
1. 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),
characterized by comprising:
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.
2. A control lever (40) according to claim 1, characterized by comprising a C-shaped lateral projection (4e) at the opposite ends of the said lever
holder (4), against which the cocking spring (10) abut, and which is formed such that
its opened section faces to the electronic circuit board.
3. A control lever (40) according to claim 1, characterized by comprising a C-shaped spring projection (11d) at the opposite ends of the said lever
supporting member (11), against which the cocking spring (10) will abut, and which
is formed such that its opened section faces to the electronic circuit board.
4. A control lever (40) according to claim 1, characterized by comprising a plurality of friction plates (19) which are placed on the lever holder
(4).
5. A control lever (40) according to claim 4, characterized in that the lower section (19b) of each friction plate is formed as a concave and comprises
at least one pressure spring (20) which interacts with a stopper plate.
6. A control lever (40) according to claim 4 or 5, characterized in that the lower section (19b) of the said friction plate is made of rubber-based material
and the upper section (19a) of the friction plate is made of rigid thermoplastic or
metal.
7. A control lever (40) according to claim 1, characterized by comprising at least one spring alignment projection (4g) on the lever holder (4)
and at least one spring alignment projection (11g) on the lever supporting member
(11) corresponding to the opposite side of the spring arm (10a) of the said cocking
springs (10).
8. A control lever (40) according to claim 1, characterized in that said printed circuit board assembly (25) comprises a resin filler (18) coated therein
so as to ensure its sealing.
9. A control lever (40) according to claim 8, characterized in that the printed circuit board housing (22) comprises a hole (22b) corresponding to the
printed circuit board pin (21a) and an elastic member (24) interposed between the
hole (22b) and the printed circuit board (21).
10. A control lever (40) according to claim 1, characterized by comprising a plurality of semicircle recesses (13b, 13c) on that side of the body
(13) facing to the printed circuit board (21), and relevant counter bushings (9, 12)
positioned in these semicircle recesses (13b, 13c).
11. A control lever (40) according to claim 1, characterized in that said upper body (13), the lower body member (14) and the printed circuit board housing
(22) are made of electrical insulating thermoplastic material.
12. A control lever (40) according to claim 1, characterized by comprising at least one external protection sheet (29).
13. A control lever (40) according to claim 12, characterized in that the contact element (23) which is in contact with the printed circuit board (21)
and reaches to the outer surface by means of a cut hole (22c) is in contact with the
external protection sheet (29) such that they interact with each other.
14. A control lever (40) according to claim 14, characterized by comprising a stopper plate (16) and at least one connecting element headspace (16c)
on the stopper plate (16) which is suitable to be filled with resin material.
15. A control lever (40) according to any one of the preceding claims, characterized in that said sensor is a Hall-effect sensor.