Welcome to Control Devices Engineering

Product Part Number: CDG-GEN-0220

Product Description: JC6000 Multi Axis Joystick with switched function.

The joystick is a 4 way joystick, (NSEW) the contacts activate at approximately 5°from centre. Multiple contacts can be engaged at the same time (NW, SW, NE, SE). The joystick allows for custom handles to be fitted.It can be used to control solenoid coils directly, providing that the current rating is within the switching capability of the joystick. Considering that higher current will reduce the life of the switches, we have made the switches a replaceable item, available ex-stock from Control Devices or you can order them from Farnell.

*IP Rating is determined by the control grip used on top of the joystick, various models exist from IP67 to IP50

Product Part Number: CDG-GEN-0181

Product Description: Electronic buffer board with 4-20mA current output.

This device is designed to regulate the power supply to the buffer any Penny and Giles joystick. It has a regulated 5V supply to the joystick, has an additional 2.5V reference voltage for center tap stabilization. Its wiper current draw will be in a magnitude of nano-amps offering very high input impedance. The device has over current, polarity and over voltage protection. The device is provided with a 16 Way harness which allows easy interconnection between the byffer board, joystick and the rest of the system.

Our buffer board project is now reach field testing – we have prvided several customers with 4-20mA, 0-10V boards to see how well they will work in the field.

We have redesigned the package that the board sits in – making it more aesthetic. for more information please see the previous article here. ( http://controldeviceseng.com/2010/07/22/buffer-pcb-to-ensure-low-current-draw-and-protect-joystick-controller/ )

He have recently commenced work on a miniature joystick designed for auxiliary control on standard control grips. The device is a simple potentiometer joystick with a similar feel to that of a standard gaming joystick. We have created a couple of packages which show the body size as well as the connector attached to the base.

We should have a working prototype in a few weeks, and we are currently seeking a local company that would be willing to perform field tests.

We are also taking into consideration the Ingress Protection for the device. It appears that we should be able to achieve at least IP65 above the panel if not or perhaps even diving depth above the panel with the appropriate rubber gaiter.

The current size of the device is 33mm (Dia) x 35mm full length.  16mm above the panel.

After a few problems with the PCB we have finally completed the first working prototype of the RS485 communications board PCB. The final package has been assembled and is ready for shipping for field testing by our customer. I have provided some photos of the finished product. A technical drawing of the functions and mechanical design is available for download here. DW-0205-CDG-GEN-0143

Case prototyping was finished today – next stage is painting the device. Picture of painted prototype to follow soon.

We have made significant progress with the RS485 communications board project. Currenty the PCB is being manufactured and all components for the first electronic assemblies have been ordered.

We anticipate the delivery of all items later this week for assembly and bench testing. We have also completed the mechanical assembly drawings of the device and it’s enclosure. We will be making the first prototype of the enclosure early tomorrow.

Some extra functions have been added to the board.

• 5V excitation voltage for energising the joystick or sensor.
• Error detection with LED indication
• RS422 connection

We have provided some further CAD images to show the progress of work thus far. For further updates please contact mark@controldevices.net

We have recently commenced work on a communications board project that which accommodate an analogue and digital joystick signal and transmit this on a RS485 bus.

RS485 Prototype PCB Layout

Essentially the devices will be designed to function with the JC6000 joystick, hence the board will accomodate all of the possible digital and analogue functions that the joystick can provide. Essentially the board will be able to receive signals from the joystick as well as provide excitation power to the joystick device, eventually allowing it to be used with more than just the JC6000 series joystick. Considering that the JC6000 can provide many function we have anticipated this and are providing the following inputs.

• 6 Analogue Inputs
• 20 Digital Inputs
• 5 x 5 Voltage supply
• 5 Analogue GND Terminals
• 4 Digital GND Terminals

We plan to house the PCB in a housing providing screw terminals for the external power and RS485 signal. the other side of the PBC will be soldered terminated directly to the harness which will connect to the joystick.

The Microprocessor we are using is capable of many different function. The device is capable of communications standards such as…

RS485 Communications Board CAD Layout

• SSI
• CAN
• RS485
• RS232
• RS422
• USB

The plan is to complete the RS485 communications protocol first and then move on to completing the USB output option. Currently we are finishing the PCB design layout for the first RS485 board we hope to have the first version assembled and working within a couple of weeks.

If you require further information about this product please let me know, you can contact me on.

Mark (Maciej) Dzidowski
Engineering Manager
Control Devices Engineering
Control Devices Group
Australia – New Zealand – Singapore – Thailand – China
02 9368 7100
0408 011 606
www.controldevices.net
mark@controldevices.net

For quite some time now, we have been asked for a basic, switch output, robust industrial joystick. Although the Penny and Giles JC6000 does already have a switched option, unfortunately it cannot be used in all application and the joystick does come with proportional output as standard.

So why cant we use this device on it’s own. Well the maximum rating is only 2A, however customers have asked for a device that can handle up to 5A with peaks as high as 15A. Also if you do damage the directional switch there is no cost effective repair path, since the existing switches are connected to a PCB board which is permanently fixed to the joystick base. We also have the proportional output which these particular customers did not need, essentially a function that is not used but paid for.

The JC6000 has an excellent mechanical gimble mechanism and is designed to last over 15 million operations. This is why we are currently in development for a modification to the joystick. We plan to utilise the mechanical strength of the gimble, and finding a solution for a high electrical life in high current applications.

JC6000 High Current Micro-switched Prototype Concept

The biggest hurdle we face is finding a switch that has a high enough operational life in a high current scenario. We are looking at a peak current of 15A, extensive research has shown that when a switch is available to handle the high current, the electrical operational life is 10,000 operations at best. Naturally lower currents yield longer life spans, some in the order of 100,000. I have found one that claimed a 2,000,000 operational like, but somehow I am sceptical of this specification, but we will do an independent test to verify this.

So what’s the solution? Well for now, the best solution would be to make the switches very easy and very inexpensive to replace. We are planning to release the replacement switches as a spare part in two configurations.

1. The switch as a stand alone replacement
2. The switch block with 2 or 4 switches attached (Depending on which configuration is required)

These switches will be field replaceable, no specialised knowledge or tooling will be required to change these devices out. We are also considering extending the cam mechanism in order to provide multiple outputs per direction, meaning more then one contact and possibly activating in different positions.

For Enquieries about this product please contact.

Mark (Maciej) Dzidowski
Engineering Manager
Control Devices Engineering
Control Devices Group
Australia – New Zealand – Singapore – Thailand - China
02 9368 7100
0408 011 606
www.controldevices.net
mark@controldevices.net

This article discussed a new project undertake by Control Devices Engineering for a solution for extreme dust and moisture. The scope of work is to taje a standard JC6000 Base and improve it’s sealing in order to cope worth the environments mentioned earlier.

JC6000-Sealed Base Prototype Close Up

There are many misconceptions as to the IP rating of a device.

“The IP Code (or International Protection Rating, sometimes also interpreted as Ingress Protection Rating) consists of the letters IPfollowed by two digits and an optional letter. As defined in international standard IEC 60529, it classifies the degrees of protection provided against the intrusion of solid objects (including body parts like hands and fingers), dust, accidental contact, and water in electrical enclosures. The standard aims to provide users more detailed information than vague marketing terms such as waterproof.” WIKIPEDIA

We find that people generally request a rating far beyond what they actually require. Hence spend their budget on devices that are over rated in relation to their actual application. When considering a device such as a joystick, you must first consider the environment the device will operate in. Things you would want to consider are the following.

• Temperature
• Humidity
• Exposure to the Sun
• Proximity to the Sea
• Dust
• Moisture
• Indoor or Outdoor Operation
• Operator
• Electrical Noise
• Shock and Vibration

The IP rating will address the following of the list above

• Moisure
• Dust
• Indoor or Outdoor (Partially)

There is a full and comprehensive list of the IP rating codes available on this site (IP CODE) From this list you could probably ascertain the correct code for your application. There will be times that the device that meets you electrical criteria may not meet your environmental criteria. We have recently embarked on an improvement project for the Penny and Giles JC6000 industrial joystick. The device is an excellent device, it have a long life capability, and is very reasonably priced.

JC6000 Prototype with sealed IP base

The device is already rated to IP65, which should be sufficient for most applications, however this rating only applies to the part of the device that is designed to be above the panel. Unfortunately leaving the base exposed to the elements below the panel. Normally this is not a problem, however we have come across applications where high humidity situations and extreme dust situations occur. Applications such as a timber drying kiln or a cement manufacturing plant, respectively.

The amounts of stem vapour in the timber mill is so high that you cannot see a foot in front of your nose, and the dust inside a cement facility gets into all sorts of gaps and crevices.

Faced with such a tough environment we made the decision to improve the base enclose for the JC6000. We essentially extended the base, and added some IP68 Glands to lock around the 16, 12 and 8 way harnesses, that still plug into the base of the joystick.  We have provided some images as to the progress of the project.

We are now in the testing stage of our design, results soon to follow.

News – We have commenced a new project which will provide our customers with electrical buffer boards which will protect the joystick from over current on the proportional output of the joystick. We are also working on buffering the directional switches.

Buffer Board for Joystick Harness with Loom Attached

We are considering a relay board that will isolate the relatively high currents required to drive solenoids. For now we are working on a 4-20mA and a voltage output module which can take various voltages and buffers them before the signal returns to the amplifier. We have created the first space prototype and we will be building the first working PCB which had a 4-20mA output.

More information to follow as the project makes progress.