WHAT IS A JOYSTICK?
A joystick is an input device consisting of a stick that pivots on a base and reports its angle or direction to the device it is controlling. A joystick, also known as the control column, is the principal control device in the cockpit of many civilian and military aircraft, either as a centre stick or side-stick. It often has supplementary switches to control various aspects of the aircraft's flight.
Joysticks are often used to control video games, and usually have one or more pushbuttons whose state can also be read by the computer. A popular variation of the joystick used on modern video game consoles is the analogue stick. Joysticks are also used for controlling machines such as cranes, trucks, underwater unmanned vehicles, wheelchairs, surveillance cameras, and zero turning radius lawnmowers. Specialist joysticks, classed as an assistive technology pointing device, are used to replace the computer mouse for people with fairly severe physical disabilities.
MANUFACTURING PROCESS
Before taking up fabrication, the product drawings are studied and a process plan for each part is prepared. Attention is bestowed on fabric ability during the design stage itself. During product fabrication following procedure is followed
Material selection-Information about several Suitable materials is selected depending on their application and their properties. In this manufacturing process, the nylon material is selected.
Process Planning-Systematic determination of the detailed methods by which parts can be manufactured economically from the initial to the finished stage is taken up.
Manufacturing-According to the process plan presented in the form of process sheets, manufacturing of each component is carried out. The machining operation can be classified into the following categories:
Pre tooling: -Raw material is cut to overall profile considering machining allowances. This operation is carried out generally sawing and flame cutting. This is also called pre-tooling.
Conventional tooling: -According to the drawing and process sheet the raw material is rough machined to the geometric features and size of the part by providing sufficient allowance for finishing. Conventional machining is generally carried out by Lathe, Milling, and shaping machines.
Failure Mode Effective Analysis (FMEA)process is performed on the manufacturing processes. They highlight possible failure modes in the manufacturing process, limitations in equipment, tooling gauges, operator training, or potential sources of error. This information can then be used to determine the corrective action that needs to be taken. The objective of an FMEA is to look for all of the ways a process or the product can fail.
Evaluating the risk of failure, the relative risk of a failure and its effects are determined by three factors
Severities (S) - the consequence of the failure should it occur.
Occurrence (O) –the probability of frequency of the failure occurring.
Detection (D) –the probability of the failure being detected
before the impact of the effect is realized. Once the action has been taken to improve the product or process, a new rating for severity, occurrence and detection should be determined and a resulting RPN calculated. For the failure modes where the action was taken, there should be a significant reduction in RPN. There should expect at least a 50% or greater reduction in the total RPNs after an FMEA. That RPN depends on the industry and the seriousness of failure.
Bill of Material- The bill of material gives a description of every component and the quantities of each used to manufacture an end product. The bill of material is generally abbreviated as BOM. The Bill of materials is hierarchical. During assembly and final inspection, BOM plays an important role.
Cost Estimation- Cost estimation aims at determining the cost of manufacturing a component (Product Assembly). It should be carried out in such a way that all factors affecting the cost are properly considered. Thus, it is the probable cost of an article before manufacturing starts. By compiling a statement of the quantities of the material required and the production time required, the probable cost is computed. The various constituents of the costs like material cost, tooling cost, machining cost, non-productive cost (factory expenses, administrative expenses, selling expenses etc.).
Material Cost- Cost incurred on the raw material used in making the product. They are direct and indirect materials
Process Cost- Cost of shaping the raw material into finished products. For this, machining time is to be calculated for each part. Machining time can be calculated by using the following formulae.
In practice, machining cost is fixed based on the experience considering the handling time, set up time etc.
Standard Components Cost: Cost incurred on purchasing the standard component used is indicated in
Total Machining Cost:
Prime Cost = Material Cost + Cost of Standard Items + Total Machining Cost = 800 + 519 + 2077 = Rs. 3396/-
Overhead Charges = 25% of Prime Cost = Rs. 849 /-
Indirect Expenses = 15% of prime cost = Rs. 509.5/-
Foot Switch cost= Prime Cost + Overhead Charges + Indirect Expenses
= 3396 + 849 + 509.5
= Rs. 4754.5/-
Testing Objective the Joystick is tested for its performance. Its performance will be done by using PCB and LED‘s in testing the performance will be assessed by relating the movement of the joystick with the glowing of LED.
It consists of an amplifier to amplify the voltage output from the potentiometer which is in millivolts up to 12V. Two PCB‘s are built for two-directional movement of the joystick and four LED‘s are used to test the four directional movements of the joystick. Different potentiometer outputs, i.e. output from two LED‘s for acceleration - brake (front-back) and other two LED‘s are for steering (left-right) are provided. By moving the joystick, the resistance of the potentiometer will be varied through the variable resistance which can predict the position of the joystick. A comparator is a device that compares two voltages and switches its output to indicate which is larger. They are commonly used in devices such as analogue-to-digital converters (ADCs). A potentiometer is connected to a comparator as an input, to get the position of the joystick. In the comparator by giving a reference voltage (Vref) will be set. As the position of the joystick is varied and when it comes to its maximum position i.e., when Vref ≤V pot, the corresponding LED will glow. Here two comparators are used for getting the position of the front, back, left side, and right-side position of the joystick. To indicate the position four LED‘s are used.
Angular Movement V/S Resistance:
The main aim of testing is to produce variable resistance at the required angle. The joystick assembly is connected to a multimeter to note the variable resistance value for different positions of the joystick.
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DISCLAIMER
The information is provided by Tecquisition for general informational and educational purposes only and is not a substitute for professional legal advice. If you have any feedback, comments, requests for technical support or other inquiries, please mail us at tecqusition@gmail.com.
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