Patent Application
20140183017
Not Applicable
Not Applicable
The present invention relates to control modules, and more particularly to a control module having a continuous cover with redundant switches that are configured to trigger a single, particular function of the control module.
Control modules are often employed to provide an interface allowing a user to manipulate functions that are triggered by the control module. For instance, material handling vehicles, such as those manufactured by The Raymond Corporation of Greene, N.Y., incorporate control modules that can be engaged by an operator to trigger functions including raising and lowering forks, increasing or decreasing truck speed, and sounding the horn. These material handling vehicles are subjected to considerable use in varying environments that can place a high demand on the mechanical and electrical robustness of the overall control module. Increasing application demands continue to challenge the bounds of typical control modules.
In light of at least the above challenges, a need exists for any increasingly robust control module providing enhancements including a continuous cover with redundant switches that trigger a single function of the control module.
In one aspect, a control module comprises a housing, a continuous cover supported by the housing, and a plurality of switches positioned within the housing in selective mechanical engagement with the continuous cover. Each of the plurality of switches is electrically configured to be capable of independently triggering a particular function when the continuous cover is moved relative to the housing.
In another aspect, a control module comprises a housing, a control board mounted inside of the housing, and a continuous cover supported by the housing. An array of dome switches is positioned within the housing adjacent to the continuous cover and integrated with the control board such that each of the array of dome switches is configured to be capable of independently triggering a particular function when the continuous cover is moved relative to the housing engaging at least one of the array of dome switches.
In yet a further aspect, a method of manufacturing a control module comprises the steps of: providing a housing defining a cavity; positioning an array of contacts within the cavity; connecting the array of contacts such that actuation of each contact in the array of contacts can individually trigger a particular function; and aligning a continuous cover with the array of contacts such that movement of the continuous cover relative to the housing triggers the particular function.
These and still other aspects will be apparent from the description that follows. In the detailed description, preferred example embodiments will be described with reference to the accompanying drawings. These embodiments do not represent the full scope of the concept; rather the concept may be employed in other embodiments. Reference should therefore be made to the claims herein for interpreting the breadth of the invention.
The concepts described below and shown in the accompanying figures are illustrative of an example implementation of the inventive concepts; however, when given the benefit of this disclosure, one skilled in the art will appreciate that the inventive concepts described herein can be modified and incorporated into many other applications. Furthermore, throughout the description terms such as front, back, side, top, bottom, up, down, upper, lower, inner, outer, above, below, and the like are used to describe the relative arrangement and/or operation of various components of the example embodiment; none of these relative terms are to be construed as limiting the construction or alternative arrangements that are within the scope of the claims.
The example control module 10 described herein is configured to allow a user to manipulate and control several features of a device (e.g., a material handling vehicle (not shown)) via the control module 10. Specifically, the control module 10 includes operationally distinct continuous covers (e.g., buttons) that can be actuated (e.g., depressed or moved) by a user to trigger a particular function associated with that button (e.g., the raising or lowering of forks of the material handling vehicle). The configuration and construction of the example control module 10 establishes a functional redundancy by associating multiple switches with each distinct button such that, for instance, actuating a specific continuous cover (e.g., a raise fork button) typically results in multiple switches (e.g., dome switches) beneath the continuous cover being actuated substantially simultaneously or at some phase of the button actuation. Each switch beneath the particular continuous cover is operatively arranged to independently and collectively trigger the identical function, thereby providing a redundant switch configuration for each continuous cover. With the fundamental concepts understood, and in light of the example control module 10 described below, one skilled in the art will appreciate the various application-specific modifications that can be made to implement the concepts into a wide variety of end uses.
With continued reference to
Turning to
With additional reference to
The membrane 36 is generally supported by the housing 16 and includes a base 48 about the perimeter of the membrane 36 that is configured to engage with a mounting surface 50 formed in a cavity 52 of the housing 16. As shown in
When the membrane 36 is assembled to the housing 16, a continuous bead 49 of silicone adhesive can be applied adjacent to the base 48 of the membrane 36 that is proximate to the mounting surface 50 of the cavity 52 (shown in
The configuration of the example raise fork button 42/lower fork button 44 with the example control board 54 and switches (described below) is best illustrated with specific reference to
Turning to the lower fork button 44, which is also formed by a continuous cover having a relatively rigid construction (e.g., such that movement of the continuous cover is generally uniform across the continuous cover), eight nibs 78 are laid out in a general array and extend from an interior surface 80 of the lower fork button 44. Similar to the nibs 66 of the raise fork button 42, seven of the eight nibs 78 are operably aligned with a mating switch (in the form of a dome switch 82), with each switch being configured to independently trigger a second function (e.g., lowering the forks). The eighth dome switch position on the control board 54 was removed to accommodate a pressure balance arrangement (described below). The dome switches 82 again include legs 83 that are secured to an outer contact ring 84 formed in the control board 54, and are centered over a central contact 86 formed in the control board 54. When the lower fork button 44 is moved toward the control board 54, at least some of the respective nibs 78 mechanically engage dome portions 85 of respective dome switches 82. Once the actuation force exceeds the defined force limit, the dome portions 85 collapse and make electrical contact with the central contact 86, completing an electrical circuit for each dome switch 82 and triggering (either individually or collectively) the raise fork function of the control module.
For completeness, the left horn button 38 and the right horn button 40 each include a single nib 88 such that when the membrane 36 is installed to the housing 16, the nibs 88 align with dome switches (not shown) secured to respective left horn contacts 90 and right horn contacts 92 integrated with the control board 54 (shown in
The example nibs 66, 78 are generally cylindrical and are integrally molded with the membrane 36. However, the nibs may have a variety of form factors, locations, and constructions, such as hemispherical members that are adhered to the back sides of the respective continuous cover. Additionally, the number and placement of the mating nibs and switches for a particular function can be modified to suit particular application requirements. Given the benefit of this disclosure, one skilled in the art will appreciate the variety of configurations that fall within the inventive concept.
In the example configuration, each of the dome switches 70 mounted to the control board 54 is capable of electrically triggering the particular function (e.g., the raise fork function) when the continuous cover (e.g., the raise fork button 42) is moved relative to the housing 16 to mechanically engage and depress the dome switches 70. Similarly, each of the dome switches 82 mounted to the control board 54 is capable of electrically triggering the particular function (e.g., the lower fork function) when the continuous cover (e.g., the lower fork button 44) is moved relative to the housing 16 to mechanically engage and depress the dome switches 82. This arrangement provides for a triggering redundancy for each distinct function. The specific functions being controlled by a control module in accordance with the inventive concepts are application specific and are not limited by the example functions disclosed herein.
A simplified electrical schematic of the example control module 10 is illustrated in
Returning to
While there has been shown and described what is at present considered the preferred embodiments, it will be appreciated by those skilled in the art that various changes and modifications can be made without departing from the scope of the invention defined by the following claims (e.g., the relative proportions and dimension of the components can be altered, and, where applicable, various components can be integrally formed or single components can be separated into multiple pieces).
