Abstract:
An intrinsic console, moveable with respect to a base between at least two locations, has one or more controllers (sliders, switches, joysticks). Typically a controller controls different devices in different locations (multi-function). The controller has at least two positions in each location, but may have different settings (slider, two-position switch—momentary or ON/OFF—three-position switch, etc.). The locations, functions, positions, and settings are microprocessor controlled, and reprogrammable. LED or LCD indicator displays can be incorporated with the controller, and similarly change with location. This reduces the absolute number of controllers necessary. The positions of levers and joysticks are digitally measured by optical emitters and detectors which pass light through apertures of known location, these measurements may be relative or absolute. The console is ideally pivotally mounted near the elbow of a vehicle or equipment operator.

Description:
This application claims priority of U.S. provisional patent application Ser. No. 60/105,207, filed on Oct. 22, 1998. 
    
    
     This invention relates to an intrinsic console and related controllers. An intrinsic console is the name for a control console, movable by the operator between two or more distinct locations, having at least one controller controlling a different device in each distinct location. The controller controls the device by the position of the controller&#39;s bat, knob, grip, lever, slider, joystick or the like. When controller&#39;s location is changed, the controlled devices are still controlled, but to change the position controlling for a specific device, the controller has to be in a specific location. As the controller is moved from one location to another, the position of the controller in the second location will be that position set in that location (which may be the same as in the first location or different). The console has location sensors which monitor the location of the console and thus the controller. Although the controller(s) may be on-off, or momentary, it is preferred that they be programmable multi-position controllers, which may have several positions (such as a gearbox) or be continuous (such as a dimmer or steering wheel). The controller is positionable, that is a microprocessor can move the controller bat, knob, grip, lever, slider or joystick to any position. So when the operator changes the location of the controller, monitored by the location sensor, a microprocessor remembers the position of the controller in that location, monitors the position by a position sensor, and without operator action moves the controller&#39;s bat, knob, grip, lever, slider, or joystick to that position. The controllers include, but are not limited to, momentary, two- and three-position switches, rotary switches, slider controllers (one-degree-of-freedom controllers), joysticks (two-degree-of-freedom controllers). The controllers designed for use with the intrinsic console are preferably programmable as to their mode of control, and this programming is intended to be changeable by the operator. It is expected that manufacturers using the controllers may restrict the degree of programming for safety and other operational reasons. 
     Although the invention is described and referred to specifically as it relates to specific components, devices and structures for intrinsic consoles and related programmable positionable multi-function multi-position controllers it will be understood that the principles of this invention are equally applicable to similar components, devices, structures and accordingly, it will be understood that the invention is not limited to such components, devices, and structures for intrinsic consoles and related programmable multi-function multi-position controllers. 
     In this application the term “location” defines a specific physical location or position of a controller, the term “position” defines a specific state of the controller, for instance ON or OFF. “Setting” defines the specific way the controller works (momentary switch, position switch, rotary switch, slider controller, joystick and the like). “Positionable” means the controller “position” can be changed by a microprocessor. “Programmable” means the microprocessor can change the controllers “setting” and device controlled. 
     PRIOR ART 
     Applicant is not aware any prior art devices. 
     The invention followed two lines of development. The intrinsic console, where a controller controlled several functional devices, and its position changed according to location, that is the changing the position of the controller for a specific device can only be done in a specific location. If a controller has a specific position in a specific location, then moving the controller to a different location will not change the effect of that position. A controller may have different positions in different locations. For example it may be ON in a first location and OFF in a second location, when the switch is moved from first to second location it will change its setting from ON to OFF as it does so. 
     The programmable multi-function multi-position switch or controller was developed separately. This allows one controller to have several different functions, each of which may have a different group of possible controller positions. 
     It is a principal object of the invention to provide an intrinsic console having at least one controller, which controls at least two devices, where the specific position of the controller for a specific device can only be changed in a specific location, other positions of the controller remaining unchanged. It is a further principal object of the invention to provide a multi-functional multi-position switch, each function having an associated group of positions which may differ from the positions of other functions. It is a subsidiary object of the invention to provide a digital position measuring system for the drive motor(s). It is a further subsidiary object that the position measuring system comprises an optical quadrature aperture counting system. It is a further subsidiary object that the position measuring system comprises a motor commutation slot counting system. Other objects will be apparent to those skilled in the art from the following specification, statement of invention claimed and accompanying drawings. 
     DESCRIPTION OF THE INVENTION 
     In one broad aspect the invention is directed to an intrinsic console mounted on a base and movable between at least two distinct locations. The console has mounted thereon at least one controller having at least two distinct positions. The controller controls different devices in different locations. Preferably the controller&#39;s position is controlled by microprocessor. Typically console location and control position are monitored by sensors. Conveniently the controller has a display indicating device controlled and controller position according to controller position and console location, this display is microprocessor controlled. The controller may have a different number of control positions in different locations. The controller is usually selected from toggle switch, slider, rotary switch, and joystick. The relative position of the console may be determined by digital optical detectors receiving radiation from electromagnetic emitters passed through an apertured optical positioning member. 
     In another broad aspect the invention is directed to a controller for a device having a lever and a microprocessor controlling a motor and the number of positions of the lever. Typically the lever positions are monitored by sensors. The lever may operate as slider, or toggle switch, which may have a plurality of distinct position settings, each position setting having at least two toggle positions. The lever is selected by the microprocessor to function as either slider or toggle switch, when the toggle switch is selected, a position setting is selected from a plurality of distinct position settings, each position setting having at least two toggle positions. The relative position of the controller may be determined by digital optical detectors receiving radiation from electromagnetic emitters passed through an apertured optical positioning member. The absolute position of the controller may be determined by digital optical detectors receiving radiation from electromagnetic emitters passed through commutation slots. 
     In a third broad aspect the invention is directed to a controller for a device having a microprocessor controlled motor driving a gear train pivoting a control element, which may be a pivotable toggle having at least two control positions, or a pivotable slider lever. The controller may have two microprocessor controlled motors drive separate gear trains pivoting a control element, each motor and gear train moving the same control element in one of two perpendicular dimensions. The controller may be a joystick, wherein the position of the joystick handle is separately determined for each perpendicular dimension is determined by digital optical detectors receiving radiation from electromagnetic emitters passed through an apertured optical positioning member. 
     The invention is illustrated but not restricted by the foregoing description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top plan view of an embodiment of the intrinsic console of the invention. 
     FIG. 2 is a front perspective view of an embodiment of the intrinsic console of the invention. 
     FIG. 3 is an internal perspective view of the embodiment of FIG.  2 . 
     FIG. 4 is a top representation of control function zones corresponding to arm positions of an embodiment of the invention. 
     FIGS. 5-7 are representations of switch programmable LCD icon displays and functionalities, slider (FIG.  5 ), toggle (FIG.  6 ), and joystick (FIG.  7 ). 
     FIG. 8 shows a part sectional elevation of a slider of FIG.  1 . 
     FIG. 9 shows an exploded view of the slider of FIG.  8 . 
     FIG. 10 shows a part sectional elevation of a toggle of FIG.  1 . 
     FIG. 11 shows an exploded view of the toggle of FIG.  10 . 
     FIG. 12 shows a part sectional elevation of a joystick of FIG.  1 . 
     FIG. 13 shows an exploded view of the joystick of FIG.  12 . 
     FIG. 14 shows a perspective view of a control circuit for a slider, toggle or one joystick motor. 
     FIG. 15 shows a perspective view of a control circuit for armrest position. 
     FIG. 16 shows various toggle rockers of the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The invention is now illustrated by reference to the drawings. Numeral  10  designates an intrinsic console, which is a primitive prototype, has armrest  12  pivoting about post  14  mounted in base  18  and passing through aperture  16  of armrest  12 . Armrest  12  has terminal controller (switch)  20  which has bat  22  movable between two positions ON and OFF. This controller has two associated microswitches  24  and  26  which are position sensors (locators) for the controller bat. Armrest  12  has a terminal transverse bottom wheel (not shown) resting on base  18 , which has two radial zones  28  and  30 , on the dividing line between these is microswitch  32 , which registers movement of armrest  12  from zone  28  to zone  30 , but does not identify the direction of movement. Microswitch  34  registers the presence of armrest  12  in contact with it, microswitch  36  also registers armrest  12  in contact with it. Intrinsic console  10  is initially activated by armrest  12  activating either microswitch  34  or  36 . All five microswitches are microprocessor (computer) linked. Activation of either microswitch  34  or  36  automatically gives the microprocessor the initial location of armrest in zone  28  or  30 . When the armrest passes microswitch  32 , the microprocessor registers that armrest&#39;s  12  location has changed. Solenoid  38  pushes or pulls the bat of the controller bat to the OFF or ON position depending on the microprocessor&#39;s instructions. The controller controls two devices, in zone  28  armrest  12  can send one of two signals to a first device, (ON or OFF), in zone  30  armrest  12  can send one of two signals to a second device (ON or OFF). It should be noted that when the zone is changed say from  28  to  30 , the microprocessor remembers the bat position in zone  28  and continues to send the signal to the device. When zones are changed, activating microswitch  32  say from  30  to  28 , the microprocessor remembers the bat position, say OFF in zone  28 , and instructs the solenoid to move the bat to the OFF position. Solenoid  38  is microprocessor controlled, however it does not resist when the operator changes the bat position. 
     Numeral  110  indicates another embodiment of the invention, wooden cover  112  has rear pivot cover  114 , arm hollow  116 , and control surface  118 . Cover  112  can be made of any suitable conventional material as would be understood by those skilled in the art. Mounted in control surface  118  are joystick  120  with programmable LCD icon display  121 , slider  122  with programmable LCD icon display  123 , and toggle  124  with programmable LCD icon displays  125  and  127 . Underneath cover  112  and supporting it is aluminum structure  126  which has lower fixed portion  128  and upper pivotable portion  130 . Lower portion  128  has attachment plate  132  with attachment slots  134  and  136  for conventional bolting or screwing to a chair or seat. Pivot support  138  is attached to plate  132  and supports pivot pin  140 . L shaped arm  142  has vertical section  144  and horizontal section  146 , on which bracket  148  holds roller  150 . Upper portion  130  has frame  152  including pivot portion  154 , and transverse bars  156  and  158 , below lower bar  158  is indent bar  160 , which has downward facing indents  162 ,  164  and  166  to receive roller  150 . Frame  152  and arm  142  are urged together by spring  168  engaging rings  170  and  172 . 
     FIG. 4 shows armrest  12  (with joystick  120 , slider  122  and toggle  124  differently arranged) can be located in three detent positions labelled  1 ,  2 , and  3 . Three possible control zone arrangements are shown  174 ,  176 ,  178 . In arrangement  174  the controls (joystick, slider, toggle) only function when armrest  12  is in a detent position, and in between there are dead zones when the controls do not function. In arrangement  176  the controls change function halfway between defaults. In arrangement  178  the controls change function when the next clockwise default is engaged. 
     FIG. 5 shows slider  122  with icon displays  182  and functionality types  184 . Slider icon displays  182  show what is controlled using conventional or easily recognizable symbols. Illustrative slider functionality types range from triple snap position,  186 , through a continuous range of light (slight)  188  and heavy (stiff)  190  resistance to movement, to an end neutral position with light  192  or heavy  194  spring return to rest, to a middle neutral position with spring return to rest with full  198  or limited  196 . FIG. 6 shows toggle  124  with icon displays  202  and  204  and functionality types  205 . Icon displays  123  and  125  are on toggle rocker  200 . Toggle icon displays  202  and  204  show what is controlled using conventional or easily recognizable symbols. Illustrative toggle functionality types  205  range from triple snap position  206  and double snap position  208 , through a continuous range of light (slight)  210  and heavy (stiff)  212  resistance to movement, to an end neutral position with light  214  or heavy  216  spring return to rest, or a snap end and opposite end neutral position with light  218  or heavy  220  spring return to rest, or a middle neutral position with spring return to rest with full range  222 . FIG. 7 shows joystick  120  with icon displays  226  and functionality types  228 . Joystick  120  has icon display  121  and joystick knob  224 . Joystick icon displays  226  show what is controlled using conventional or easily recognizable symbols. Illustrative joystick functionality types  205  range from freely positionable  230 , freely positionable middle spring return  232 , cross middle spring return  234 , slider equivalent spring return  236 , limited range positionable middle spring return  238 , freely positionable offset spring return  240 , transmission snap position shifter  242 , manual gearshift with snap position and middle spring return  244 . As those skilled in the art appreciate these arrangements are illustrative only, numerous variations on the slider and toggle arrangements are possible and these may be combined with interminable variation on the joystick. 
     FIGS. 8 and 9 show slider  122  which has case  246 , with slider knob  180  mounted by set screw  262  on slider rod  248 , which is received in gear segment  250  which is pivotally mounted in recess  249 , rod  248  is secured to gear segment  250  by set screws  251 . Gear segment  250  meshes with small gear  252  of transmission gear  253 , which is mounted on pivot shaft  255  on which it is held by retainer ring  257 . Large gear  254  of transmission gear  253  meshes with bevel gear  256  mounted on shaft  258  of brushless DC motor  260  secured by screws  262  to body  246 . On shaft  258  is optical positioning disc  264 , whose position is measured by sensor, encoder  266  (phototransistor). Slider  122  also has cover  268  in which are LCD cover  270  and LCD display  272 . Circuit board  274  contains a controller card for motor  260  and a display card for LCD display  272 , which is mounted inside case cover  276 , secured to case  246  by screws  278 , numeral  280  indicates chips and the like on circuit board  274 . 
     FIGS. 10 and 11 show toggle  124 , which has rocker  200  in case  284  pivotally mounted on upper rocker shaft  282 , as is gear sector  286  which engages small gear  288  of transmission gear  290 , which is pivotally mounted on lower rocker shaft  291 . Large gear  292  of transmission gear  290  engages bevel gear  294  mounted on shaft  296  of motor  298 , which is attached to case  284  by screws  297  and washers  299 . Preferably rocker  200  has LCD covers  300  mounted therein over small LCD displays  302 . Rocker  200  is seated in rocker block  304  and rocker cover  308  which are held in place by dowels  306  and rocker grommet  310 . Screws  309  secure rocker cover  308  to case  284 . Gear sector  286  is held on upper rocker shaft  282  by retainer ring  312 , similarly transmission gear  290  is held on lower rocker shaft  291 , by retainer ring  314 . Bevel gear  294  is secured to shaft  296  by set screws  316 . Optical positioning disc  318  is read by sensor, encoder (phototransistor)  320 . Circuit board  322  contains a controller card for motor  298  and a display card for LCD displays  302 , which is mounted inside case cover  324  secured to case  284  by screws  326 , numeral  328  indicates chips and the like on circuit board  322 . 
     FIGS. 12 and 13 show joystick  120 . Joystick handle  330  has tube  336  in which is joystick push button  332  and joystick push button cover  334 . Joystick handle  330  fits onto joystick shaft or rod  338 , shaft ring lock  340  and shaft bushing  342  join handle  330  to flexible joystick boot  344  which sits on boot ring lock  346  and boot ring  348 , which may be independently rotatable of shaft  338 . Boot ring  338  rests on top plate  350 , which has LCD aperture  352  beneath which are LCD cover  354  and LCD display  356 . Shaft  338  is directly attached to block  358  which may pivot about lower joystick shaft  360  and lower joystick shaft  362 . When it pivots about shaft  360  so does sector gear  364  engaging small gear (not shown) of transmission gear  366 , large gear  367  engages bevel gear  368  on shaft  370  of brushless DC motor  372 , optical positioning disc  374  is on shaft  370 . When shaft  338  pivots about shaft  362 , it moves yoke  376  and thus sector gear  378  about shaft  380  engaging small gear  382  of transmission gear  384  mounted on shaft  385 . Large gear  386  of transmission gear  384  engages bevel gear of  388  of shaft  390  of motor  392 , optical positioning disc  394  is mounted on shaft  390 . Position sensors (emitters and detectors), not shown are mounted to exactly locate the rotational positions of optical positioning discs  374  and  394 . Round plate  396  is joined to joystick base  398  by screws  400 . Circuit boards  402  (motor control) and  404  (LCD display) suitably mounted within side plate  405  and side cover  406 , secured to base  398  by dowels  407  and screws  408 . LCD cover plate  410  is secured by screws  412  and  414 . 
     FIG. 14 shows a circuit where control is supplied by computer or microprocessor  416  through  25  pin cable  418 , and power is supplied by 12 volt battery  420  by cable  422  to circuit board  424  which may be one or two cards, including motor controller  426  and display controller  428 . Motor controller  426  supplies power through three wire supply  430  to brushless DC motor  432 . Display controller  428  controls one or more LCD displays  436  through wires  434 . Motor position is monitored and controlled through motor controller  426 . Mounted on shaft  438  is optical positioning disc  440 , with quadrature holes  442  and commutation slots  444 , monitored by sensor/encoder  446  which has infrared emitters  448  and detectors  450 . Encoder  446  converts rotational position to digital signal, quadrature measurement gives relative position, commutation measurement gives absolute position. 
     FIG. 15 similarly shows registration of armrest  12  position, a linear or curved array of quadrature holes  452  and commutation slots  453  are present within armrest  12 , also within armrest  12  are infrared emitters  456  and detectors  454  connected to computer  416 . Either emitters and detectors are fixed and holes and slots move with armrest  12 , or holes and slots are fixed and emitters and detectors move with armrest  12 . Either way the exact location of armrest  12  is known. 
     FIG. 16 illustrates a sample of the variety of toggle rockers which may be used in the controller. 
     All computer joysticks tell a computer where the handle is positioned at a given moment, by providing x-y axis coordinates of the handle, conventionally the x axis is side to side, the y axis forward and backward at 90° to the x axis. The base of the handle is connected to a pivoting yoke allowing the handle to move freely in any direction. Instant slider and toggle are the same as the joystick except they can move freely only on one axis. Position sensors attached to each axis of joystick, slider and toggle respond to the axis coordinates and send signals to the axis controller that the software uses to interpret the position of the joystick, slider or toggle. The 25 pin parallel port can handle 4 axis controllers 15 displays and the arm. Generally a discharging variable resistor potentiometer-capacitor, an analogue system, is used to estimate joystick position. Instant invention uses a digital system, a non-contact optic sensor generating a digital signal, because nalogue is not accurate enough. Optical quadrature sensors are used which count each hole in the optical positioning disc four times, and also commutation control on the brushless DC motors. Although the devices employ force feed back, there is no time factor, the main factor is position which generates force, with the force depending on function in both senses, mathematical relationship, and task controlled. It was found that for effective position control normal electrical servomotors were insufficient, because of their inertia (moment of rotation) they did not react quickly enough to feed back. The brushless DC motors used have very low inertia sufficient for quick response. A typical long reasonably slender brushless DC motor is used, with magnets on the rotating shaft (armature) and surrounding stationary coils, and no commutator. Brushless makes the motor reliable for a long period. Since motor only does a few revolutions over the entire stroke, any commutator will not self clean by wiping action, also since the motor tends to hunt by the way it&#39;s controlled, any commutator may arc. Experiment has showed the motor must be slender for low inertia, so the armature can accelerate and decelerate under reasonably low torque. High armature inertia requires lots of power and time to get spinning, and lots of power and time to stop spinning, and cannot respond quickly. Since the motor must be slender to minimise inertia, it must be long to generate adequate power, which adds torque and inertia, but less inertia than extra width. The motor should be 100% sealed for durability. The shaft should have an adequate diameter to attach gears and encoders. The casing should be machined for a pilot to centre the motor and should have adequate mounting bosses. The shaft should have a flat spot for aft registration of preferably non-adjustable, properly registered gears and tight enough tolerances for back lash. The motor should be assemblable, and disassembable without special tools. Its wires should be of adequate gauge for easy attachment without breakage, as thin wires are mechanically weak. The motor itself should be removable from outside by two adequately sized screws, bevel gears should remain in position on the motor shaft. Motor wires should be attached to a terminal block, thus avoiding removal stripping. The bevel gear-transmission gear reduces motor rpm substantially. The gears themselves should be durable, light duty, non-lubricated, slippery plastic, for instance Delrin, nylon or Teflon, amongst others, with adequate sized teeth allowing durable, smooth, and reliable operation, registration error without skipping teeth during rotation, and reasonable wear without skipping teeth. Minimal internal airspace is required to maximise internal space utilisation, minimise internal air space and minimise external size. 
     The embodiment of FIG. 1 worked satisfactorily as a slider; a three-position on switch, (such as a three speed motor in a windshield wiper); a three-position (momentary on) on on switch; a three-position on on (momentary on) switch; a three-position (momentary on) on (momentary on) switch; a two-position on on switch; a two-position on (momentary on) switch; and a resistant position, where the switch bat can be moved anywhere desired and then fights further movement with full motor power. As those skilled in the art appreciate any active switch position (ON) can be replaced with an inactive switch position (OFF). The switch bat or lever can also be positioned, in the then version there are up to 33 programmable distinct positions in an arc of about 400, but as those skilled in the art would appreciate the number of positions can be greatly increased effectively limited by sensor position measurement error or motor position control error, whichever is larger. The switch setting is selectable (and changeable) by connecting the motor microprocessor to a parallel printer port on a PC and selecting a setting from menu. Disconnection leaves the switch setting in place. 
     As those skilled in the art would realise these preferred described details and materials and components can be subjected to substantial variation, modification, change, alteration, and substitution without affecting or modifying the function of the described embodiments. 
     Although embodiments of the invention have been described above, it is not limited thereto, and it will be apparent to persons skilled in the art that numerous modifications and variations form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention.