Abstract:
Provided is an intelligent multi-axial intuitive joystick suitable for use by both left-handers and right-handers and applicable to machine tools, measuring equipment, cars, and so on, which require moving instructions. The joystick features at most four-axis output control, multiple output modes to select from, a dead-band setting function, axial angle shift detection, origin calibration, feedback from axial force application, Z- and C-axis intuitive operation, working status display, and system surveillance.

Description:
BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The present invention relates to an intelligent multi-axial intuitive joystick which is suitable for use by both left-handers and right-handers, capable of multiple special functions, and applicable to various machines requiring moving instructions. 
     2. Description of Related Art 
     Unidirectional or multi-directional operation is often required in general machine tools, industry-specific machinery, application-specific tools, or transmission equipment, for controlling the movement of various mechanisms, such as the forward/backward or upward/downward movement of a mechanical shaft or arm. Therefore, the advent of control joysticks has brought tremendous convenience to related operators. An operator only has to hold and gently push the joystick forward, backward, leftward, or rightward to effectively control the movement of different machine parts. In a nutshell, the joystick makes it possible to control everything in one hand. 
     Commercially available hand-operated joysticks with a single-spring center-resetting mechanism typically provide biaxial control along the X- and Y-axes. The so-called biaxial control generally includes control along the X-axis, whereby a certain mechanism is moved forward and backward; and control along the Y-axis such that the mechanism can be moved leftward and upward, as well as rightward and downward. Of course, biaxial control also includes controlling the mechanism diagonally, such as by pushing the joystick in directions between the X- and Y-axes, thus moving the mechanism forward, leftward, and upward at the same time; or forward, rightward, and downward at the same time; or backward, leftward, and upward at the same time; or backward, rightward, and downward at the same time. However, biaxial control joysticks do not provide precise diagonal control (i.e., control along directions between the X- and Y-axes) and therefore may sometimes lead to incorrect operations. 
     In consideration of the foregoing, the joystick industry has developed the triaxial (X-, Y-, and Z-axis) joystick with an additional rotating element, wherein the head of the joystick is rotatable to control the movement of one or another mechanism. More specifically, in such a triaxial control unit, control along the X- and Y-axes corresponds to forward, backward, leftward, and rightward movement; and control along the Z-axis corresponds to upward and downward movement, wherein the correspondence between the X-, Y-, and Z-axes and the various moving directions may vary. 
     Although the additional Z-axis offers convenience in operation, the triaxial joystick still has its disadvantages. First of all, control can only be carried out along the three axes. Secondly, as the control mechanism of the Z-axis secondary controller consists in rotating the head of the joystick, it is often confusing to the operator whether the clockwise or counterclockwise rotation corresponds to forward, backward, leftward, rightward, upward, or downward movement, and such confusion may cause incorrect operations of serious consequences. The major drawback of this design is that the operation required is not intuitive; in other words, the operation does not conform to the habits of the human body. 
     In addition, neither the biaxial nor the triaxial joystick has a dead band. Therefore, if the joystick is touched or shaken by accident, an abnormal instruction or an incorrect operation may be activated and result in immediate danger. 
     In contrast to the design concept of dead bands, an operator trying to operate the joystick and applies a force thereto may still move the joystick by mistake and give rise to incorrect operations. 
     Moreover, during the manufacturing process of a joystick or after the joystick has been used for some time, it is often very difficult for the joystick to return exactly to the intersection point of a cross, i.e., the point (0, 0) on the X-Y plane, when the joystick resumes its original position. In practice, a joystick tends to be offset slightly from the original center point. However, if the offset position is used as the origin from which the joystick is re-activated to control the movement of a certain mechanism, subsequent errors or incorrect operations will be aggravated. This phenomenon is mainly due to the lack of an origin calibration function. 
     Besides, a user of the conventional joystick will not receive reliable feedback from the joystick in hand of the magnitude of force applied to the joystick. Also, the conventional joystick does not have an axial-direction limiting element and therefore does not provide effective control along non-diagonal directions. 
     In addition, the conventional Z- and C-axis intuitive operation requires the use of the thumb. However, as the dexterity of the thumb is different between the left and right hands, the operation may be clumsy. 
     It is also well known that the conventional joystick does not have a working status display function. Hence, there is no information available for the operator to know whether the joystick is in a standby mode or is out of order, let alone the magnitude of force applied or the distance moved. 
     The conventional rotary secondary joystick member tends to be mistaken. Further, the conventional joystick does not provide connection for system surveillance. According to above description, the conventional joystick obviously leaves much room for improvement. 
     BRIEF SUMMARY OF THE INVENTION 
     In view of the drawbacks of the conventional hand-operated joysticks, the inventor of the present invention made extensive research and finally developed a multi-axial intuitive joystick suitable for use by both left-handers and right-handers, as disclosed herein. 
     The joystick of the present invention is additionally provided with a secondary joystick member corresponding in position to a user&#39;s thumb when the joystick is held in the user&#39;s hand. Thus, the joystick of the present invention is capable of four-axis output control, has the functions of various devices, and can reduce the costs of production and use. 
     The joystick of the present invention has a top end provided with a switch which is selectively connectable to serial-signal, digital-signal (1/0), and analog-signal programs built-in a circuit board, thus allowing the user to select the desired output mode. 
     The joystick of the present invention includes a magnetic sensor built-in with a microprocessor control circuit that defines a dead band. Therefore, if the joystick is only slightly moved within a predetermined radius from a center point, no actions will be activated, and incorrect operations are effectively prevented. 
     In order to avoid incorrect operations which may otherwise result from touching or shaking the joystick by mistake or which depart from the operator&#39;s intention, the joystick of the present invention is particularly configured for axial angle shift detection. When the operator applies a force to the joystick, the distance moved or the angle tilted must be larger than a pre-set value for an instruction to be activated. This design can also prevent operations which may otherwise result from touching or shaking the joystick by mistake or which are contrary to the operator&#39;s intention. 
     In the joystick of the present invention, the microprocessor control circuit is provided with an origin calibration circuit. Hence, when the joystick resumes its original position, either during the production process or after use, the point to which the joystick returns is used as the origin, thereby minimizing operational errors or incorrect operations. 
     According to the present invention, the head of the joystick is provided with a fulcrum ring having a surface formed with diamond pyramid-shaped projections. Thus, the magnitude of force applied and the distance moved can be known by feedback from the pressure of a spring, allowing the operator to determine for sure whether or not the force is applied along the non-diagonal X- and Y-directions. 
     The joystick of the present invention can be provided with a cross-shaped non-diagonal direction limiting element having a cross-shaped opening so that, when biaxial or four-axis output applies, the output is limited to only one non-diagonal direction at a time. This design is intended to prevent incorrect instructions or incorrect operations and is particularly useful for machinery whose operation is limited to non-diagonal directions. 
     According to the present invention, a light-permeable ring is provided at the head of the joystick, and a light-emitting diode (LED) is connected to a circuit on the circuit board so as to emit light and provide specific information to the operator as to whether the joystick is in a standby mode or out of order, as well as the magnitude of force applied and the distance moved. 
     According to the present invention, the head of the joystick is rotatable to various positions, thus rendering the joystick suitable for use by both left-handers and right-handers. Besides, the secondary joystick member is based on an intuitive design; in other words, the secondary joystick member is configured to be pushed forward, backward, leftward, and rightward according to the operator&#39;s intuition. 
     The joystick of the present invention is provided with a system surveillance device. When connected to the joystick, the system surveillance device can rapidly determine whether or not the vectors of the joystick are normal. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a perspective view of the present invention; 
         FIG. 2  schematically shows the simultaneous four-axis (X-, Y-, Z-, and C-axis) control of the present invention; 
         FIG. 3  is an exploded perspective view of the present invention; 
         FIG. 4  is an exploded perspective view of a small secondary joystick member according to the present invention; 
         FIG. 5  schematically shows the dead band of a primary-joystick-member digital processing sensor according to the present invention; 
         FIG. 6  is a perspective view of a fulcrum ring according to the present invention; 
         FIGS. 7-A  to  7 -F schematically show feedback from axial force application, enabled by the fulcrum ring of the present invention according to the compression ratio of a spring; 
         FIG. 8  is a top view of a cross-shaped non-diagonal direction limiting element according to the present invention; 
         FIGS. 9-A  to  9 -E schematically show how the present invention is equally suitable for use by left-handers and right-handers; 
         FIG. 10  is a top view of an indicator lamp circuit board according to the present invention; 
         FIG. 11  is a sectional view showing light emission by the indicator lamp circuit board through an indicator lamp ring of the present invention; 
         FIG. 12  is a schematic drawing showing the joystick of the present invention connected to a system surveillance device; 
         FIG. 13  is a schematic view of an embodiment of the joystick of the present invention without the small secondary joystick member; 
         FIG. 14  is a schematic view of an embodiment of the joystick of the present invention without a pushbutton switch; 
         FIG. 15  is a schematic view of an embodiment of the joystick of the present invention without the small secondary joystick member and the pushbutton switch; and 
         FIG. 16  is a schematic view of another embodiment of the joystick of the present invention without the small secondary joystick member and the pushbutton switch. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1 , according to the present invention, a multi-axial intuitive joystick suitable for use by both left-handers and right-handers includes a primary joystick member  1  and a small secondary joystick member  5  attached to the primary joystick member  1 . As shown in  FIG. 2 , the joystick of the present invention is capable of four-axis control, namely control along the X-, Y-, Z-, and C-axes. 
     Referring to  FIG. 3 , the primary joystick member  1  includes a box-shaped base  10 . The box-shaped base  10  is provided therein with an internal partition  11  centrally formed with an aperture  111 . A control mainboard  2  is fixedly provided at a lower end of the partition  11 . The box-shaped base  10  has a bottom end closed by a base lower cover  12 . 
     The control mainboard  2  is provided with a microprocessor control circuit which includes a switch program for selecting among serial-signal, digital-signal, and analog-signal programs; a dead-band setting program; an axial angle shift detection program; an origin calibration circuit; a primary-joystick-member digital processing sensor  21 ; input connector terminals  22  and  23 ; an output connector terminal  24 ; and a system surveillance connector terminal  25 . 
     A copper-ring fixing seat  13  is fixedly provided above the internal partition  11  of the box-shaped base  10  and centrally formed with an aperture  131 . A ball stick  16  is inserted through and rotatably installed on the copper-ring fixing seat  13  by means of an upper copper ring  14  and a lower copper ring  15 . The ball stick  16  has a ball. A magnet  161  is fixedly provided at a lower end of the ball and corresponds in position to the primary-joystick-member digital processing sensor  21 . The ball stick  16  also has an upper part formed as a shaft, which passes through the aperture  131  of the copper-ring fixing seat  13  and extends upward. 
     Mounted on the copper-ring fixing seat  13  are a fulcrum ring  17  and a cross-shaped non-diagonal direction limiting element  18 , wherein the fulcrum ring  17  is provided with diamond pyramid-shaped projections  171 , and the cross-shaped non-diagonal direction limiting element  18  is formed with a cross-shaped opening  181 . A base upper cover  19  above the copper-ring fixing seat  13  closes an upper end of the box-shaped base  10 . 
     The ball stick  16 , which passes through the aperture  131  of the copper-ring fixing seat  13  and extends upward, has an upper end located above the copper-ring fixing seat  13  and inserted into a sliding block  3 . A spring  32  is mounted around a neck  31  extending upward from the sliding block  3  and has an upper end connected to a handle base  33 . An angle fixing plate  34  rests on the handle base  33  and is covered by a rotating seat  35 , wherein the angle fixing plate  34  is formed with symmetric positioning blocks  341 , and the rotating seat  35  has a circular groove  351 . The circular groove  351  is inserted by a screw rod  36 , a sleeve  361 , and a spring  362 , while the handle base  33  is laterally inserted by a spring pin  331 . Thus, the handle base  33 , the angle fixing plate  34 , and the rotating seat  35  are assembled into a one-piece unit capable of being rotated to different positions. In consequence, the primary joystick member  1  can be rotated to and positioned at different angles and be comfortably used by left-handers as well as right-handers. 
     A flat washer  37  is placed in the rotating seat  35  from above. Moreover, an indicator lamp ring  38  and an indicator lamp circuit board  381  are fixedly provided on an upper side of the rotating seat  35 . A handle upper cover  4 , along with an upper ring of a rubber dust guard  41 , is fixedly provided on the rotating seat  35  via a flat washer  39  located above the indicator lamp ring  38 . The rubber dust guard  41  has a lower ring fixedly provided on the base upper cover  19  via a main-body fixing plate  42  and a dust-guard pressing cover  43 . Thus, a basic hand-operated joystick is completed. 
     The handle upper cover  4  has a top end formed with a hole  44  and an a lateral portion formed with another hole  45 , wherein the hole  44  is configured to receive a pushbutton switch  46 , and the hole  45  is configured to receive the small secondary joystick member  5  capable of X- and C-axis control. 
     Referring to  FIG. 4 , the small secondary joystick member  5  includes a secondary-axis fixing nut  51 , a secondary-axis base main body  52  resting partially on the secondary-axis fixing nut  51 , and an O-ring  581  sandwiched therebetween. Received in the secondary-axis fixing nut  51  are the secondary-axis base main body  52 , a secondary-axis ball stick  53 , a secondary-axis upper copper ring  54 , a secondary-axis lower copper ring  55 , a secondary-axis copper-ring spacer  551 , a control secondary circuit board  56 , a secondary-axis fixing cover  57 , and a secondary-axis fixing seat  58 , wherein the secondary-axis ball stick  53  extends upward. 
     The secondary-axis ball stick  53  has an upper part formed as a shaft inserted into a secondary-axis sliding block  59 . A spring  592  is mounted around a neck  591  extending upward from the secondary-axis sliding block  59  and has an upper end inserted into a secondary-axis spring stopping plate  593  and fixed in position by a C-ring  594 . After a secondary-axis rubber dust guard  595  is mounted on the secondary-axis base main body  52 , the secondary-axis rubber dust guard  595  and a secondary-axis knob  597  located thereabove are fixed in position by a secondary-axis upper fixing cover  596 , thus completing the small secondary joystick member  5 . 
     As with the ball stick  16 , the secondary-axis ball stick  53  has a ball, whose lower end is fixedly provided with a magnet  531 . Likewise, a secondary-joystick-member digital processing sensor  561  is provided on the control secondary circuit board  56  and corresponds in position to the magnet  531 . 
     As the magnet  161  of the ball stick  16  moves, the primary-joystick-member digital processing sensor  21  on the control mainboard  2  performs calculation and outputs the calculation result directly through the output connector terminal  24 . 
     On the other hand, the calculation result of the control secondary circuit board  56  of the small secondary joystick member  5  is connected to the input connector terminal  22  of the control mainboard  2  through a connector  562  at an end of an extension wire, so as to be supplied to the control mainboard  2 . The pushbutton switch  46  is connected to the other input connector terminal  23  of the control mainboard  2  through a connector  461  at an end of an extension wire. In addition, the indicator lamp circuit board  381  is provided with an LED element  382  and is electrically connected to the input connector terminal  23  through a connector  383  at an end of an extension wire, so as for the control mainboard  2  to supply electric power and signals to the indicator lamp circuit board  381  according to the operational state of the joystick, and for the LED element  382  on the indicator lamp circuit board  381  to emit light toward the indicator lamp ring  38 . 
     As shown in  FIG. 3 , the pushbutton switch  46  works in conjunction with the serial-signal, digital-signal, and analog-signal programs of the control mainboard  2  so as to provide multiple output modes to select from. 
     Referring to  FIG. 5 , the primary-joystick-member digital processing sensor  21  on the control mainboard  2  has a dead band zone  211  set by the dead band setting program of the control mainboard  2 . Thus, when the primary joystick member  1  is touched or shaken by accident and hence causes a center point of the magnet  161  of the primary joystick member  1  to move slightly within a predetermined radius from a center point of the dead band zone  211 , no actions are activated. 
     The primary-joystick-member digital processing sensor  21  on the control mainboard  2  works in conjunction with the axial angle shift detection program of the control mainboard  2  in such a way that, when an operator trying to move the primary joystick member  1  applies a force thereto, the distance moved or the angle tilted must exceed a predetermined value in order to activate an instruction. Thus, incorrect operations which may otherwise result from touching or shaking the primary joystick member  1  unintentionally or which are contrary to the operator&#39;s intensions are prevented. 
     The primary-joystick-member digital processing sensor  21  on the control mainboard  2  also works in conjunction with the origin calibration circuit of the control mainboard  2 . Therefore, even if the primary joystick member  1  moves to a point other than the original center point when resuming its original position, either during manufacture or after use for some time, that particular point will be re-set as the origin to thereby reduce operational errors or incorrect operations. 
     The diamond pyramid-shaped projections  171  on the fulcrum ring  17  function in the following manner. Referring to  FIG. 6  and  FIGS. 7-A  through  7 -F, when the ball stick  16  is moved, the relative position between the sliding block  3  and the diamond pyramid-shaped projections  171  changes, thus compressing the spring  32  by different amounts, and therefore resistance feedback from the spring  32  varies. When the primary joystick member  1  is moved along non-diagonal directions, the compression of the spring  32  is relatively small, and hence the resistance felt by the operator is relatively small; in other words, the primary joystick member  1  can be moved without much effort. However, when the primary joystick member  1  is moved diagonally, the spring  32  undergoes relatively large compression, meaning that the operator must feel relatively great resistance and has to exert much force. Thus, the feedback from force application allows the operator to know the distance and direction of movement as a reference for operation. Compared with the conventional single-spring center-resetting mechanisms, which react regardless of the direction of force application and therefore do not provide operational feedback, the present invention is truly inventive and non-obvious. 
     Referring to  FIG. 8 , due to the cross-shaped opening  181  of the cross-shaped non-diagonal direction limiting element  18 , only one non-diagonal output is permitted at a time when the joystick is operated. This design is especially suitable for use by machinery requiring only non-diagonal control and serves to prevent incorrect instructions or incorrect operations. 
     With reference to  FIGS. 9-A  to  9 -E, after the handle base  33 , the angle fixing plate  34 , the rotating seat  35 , the screw rod  36 , and the spring pin  361  are assembled together, the primary joystick member  1  can be rotated to and positioned at different angles, so as to be used by left-handers as well as right-handers. Furthermore, the small secondary joystick member  5  is configured for non-rotational control. More specifically, the small secondary joystick member  5  is configured for intuitive operation and can be pushed upward, downward, leftward, and rightward according to the operator&#39;s body orientation. 
     Please refer to  FIG. 10  and  FIG. 11  for the indicator lamp ring  38  and the indicator lamp circuit board  381 . As mentioned previously, the indicator lamp circuit board  381  is provided with the LED element  382 . The control mainboard  2  supplies electric power and signals to the indicator lamp circuit board  381  according to the operational state of the joystick, such that the LED element  382  on the indicator lamp circuit board  381  emits light toward the indicator lamp ring  38 . 
     Referring to  FIG. 12 , the system surveillance connector terminal  25  of the control mainboard  2  allows the joystick of the present invention to be connected to a system surveillance device  6 . The system surveillance device  6 , once connected to the joystick, can rapidly determine whether or not the vectors of the joystick are normal. 
     The primary joystick member  1  of the present invention can be implemented without the small secondary joystick member  5 , as shown in  FIG. 13 ; or without the pushbutton switch  46 , as shown in  FIG. 14 ; or without the small secondary joystick member  5  and the pushbutton switch  46 , as shown in  FIG. 15  and  FIG. 16 . 
     In short, the joystick having the foregoing design and structure is capable of simultaneous four-axis (X-, Y-, Z-, and C-axis) output control, allows selective switching of multiple output modes, can be set with a dead band, is suitable for use by both left-handers and right-handers, and provides such functions as axial angle shift detection, non-diagonal direction limitation, origin calibration, feedback from axial force application, Z- and C-axis intuitive operation, working status display, and system surveillance.