Jane Kamentser - White Sands Missile Range Workshops...Technology Advantages Disadvantages Potentiometers • Industrial versions available in low cost packages (military versions

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8/27/2004 1

Advancing Man-Machine Interfaces Through Embedded Force Measurement Technology

Jane Kamentser

Engineering Inc.

Expanding technology limits through innovation

Bokam

8/27/2004 2

Man-Machine Interface Requirements

• Electronically controlled interfaces and control-by-wire becoming standard in most military applications

• Military applications require precision not needed in industrial and commercial applications

• Robustness and survivability requirements in military applications are contrary to the low cost approach requirements of industrial and commercial interface product lines.

• Reliability requirements present in military applications are significantly higher then even the most “high rel.” industrial applications

Engineering Inc.


Bokam

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Military Man-Machine Interface

• Control of high precision optics - computer inputs for precision optics and fire control systems

• Computer input for mobile computing and communications systems

• Submersible electronics inputs.• Fly-by-wire

Engineering Inc.


Bokam

8/27/2004 4

Three District Approaches

• Position Proportional• Force Proportional• Non-proportional

Engineering Inc.


Bokam

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8/27/2004 5

Position Proportional Approach

Advantages– Easier for untrained people to use– More intuitive– Has easily definable end conditions

Disadvantages– Requires extra space for movement of handle– More complex internal mechanism– More prone to wear and degradation in

conventional joysticks– Lower precision

Engineering Inc.


Bokam

8/27/2004 6

Force Proportional Approach

Advantages– Highly precise– Smaller Space requirements in system– Less complexity in input device– Higher reliability

Disadvantages– Not intuitive for untrained operators– Over-force potential

Engineering Inc.


Bokam

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8/27/2004 7

Non-Proportional Approach

Advantages– Low Cost– No over-force protection required

Disadvantages– Can only control on-off functionality– Switches are unreliable– No precision

Engineering Inc.


Bokam

8/27/2004 8

Industrial Approaches to Man-Machine Interface

Standard Position Proportional Solutions– Potentiometer based joysticks– Optical joysticks and input devices– Hall-effect input devices– Industrial high-rel switches

Force Proportional Solutions– Strain Gages based systems

Non-Proportional– Switches are activated when levers are moved

Engineering Inc.


Bokam

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8/27/2004 9

Conventional Man-Machine Interface Solutions

Engineering Inc.


Bokam

Technology Advantages DisadvantagesPotentiometers • Industrial versions available

in low cost packages(military versions extremelyexpensive)

• Position Proportional

• Poor reliability• Require complex internal mechanisms• Prone to damage due to environments and dirt• Moving/rubbing parts wear easily• Low Life• Military and high reliability devices extremely

expensiveOptical • Low Cost

• Position Proportional• Required complex internal mechanism• Prone to damage due to environments and dirt• Low life

Hall-effect • Extremely Low Cost• Position Proportional

• Extremely susceptible to EMI

Switches • Low Cost • No position proportional options available• Noisy• Prone to damage due to environments and dirt• Low life• Poor reliability

Conventional straingages

• Force proportional• No moving parts• Increased reliability over

other technologies listed

• High cost of strain gage application• Limited configurations• Cross-talk• Not time or temperature stable• Susceptible to noise• No position proportional options available

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The Bokam Approach

Adapt High Reliability Sensor Technology to Input Devices to create systems that:

• High reliability and extreme live

• Have no moving or rubbing parts that can wear over time

• Provide Both a force proportional and a position proportional configuration in the same basic package size

• Develop an input device product line based on building blocks that can be combined to solve the most obscure application requirements without substantial NRE effort

• Create a cost sensitive product line.

Engineering Inc.


Bokam

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8/27/2004 11

The Base Technology

Engineering Inc.


Bokam

� Application and firing of strain sensitive materials directly into the diaphragm or substrate.

� Resulting element contains an imbedded set of strain gauges that do not rely on bond lines or epoxy for adherence to the substrate.

� Elements are deposited onto the substrate in a full whetstone bridge configuration.

� New proprietary processing techniques have been developed to allow for the deposition of strain gauge materials onto stainless steels and pin-corrosion resistive steels while maintaining dielectric isolation between the gauge and the base material.

� Proprietary barrier creation materials and processes are used to limit ion migration and create extreme temp solder joints.

8/27/2004 12

The Base Technology

Engineering Inc.


Bokam

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8/27/2004 13

The Base Technology

Engineering Inc.


Bokam

8/27/2004 14

The Base Technology Capabilities

Engineering Inc.


Bokam

� Un-amplified outputs of full bridge sensor with 10V applied can be as high as 150-200mV (with 100mV as typical output with high safety margin)

� Operating temperatures from cryogenic to 500F� Output stable over time and temperature� Technology and processes adaptable to low cost high volume OEM applications

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The Bokam Approach - Notable Achievements

Engineering Inc.


Bokam

Aurora product line named EDN Magazine Innovation of 1997 Finalist DX-300 Series of Sensors named Editors Choice for outstanding sensor development by Electronic Products Magazine DX-300 Series named EDN Magazine Innovation of the year for 1998DX-400 Series named Best of Sensors Show by Editors of Sensors Magazine for 1999DX-300M Series named in best 100 new products for 1998/1999 by leading European Medical Design Magazine

The Smart Washer™ Named Best of Sensors Expo 2000

Developed an engine embedded, production bearing thrust measurement system

Developed a direct percent aeration, foam measurement and direct pump cavitation detection system and technology

8/27/2004 16

Technology Advantages

Engineering Inc.


Bokam

Strain measurement circuitry embedded in the steel or ceramic surface.No organic materialsHigh gage factor and sensitivityIncreased stability and reliabilityIncreased survivability and life expectancyProcess highly automated and repeatableManufacturing processes lend themselves to high volume production

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Technology Advantages -Thermal Stability

Engineering Inc.


Bokam

Room Temp Cal vs Cal at 140F

Pressure (PSI)

Out

put (

mV

)

Room Temp Cal

High Temp Cal

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Technology Advantages -Repeatability and Stability

Engineering Inc.


Bokam

Five Cycles with Version 05 Diaphragm and 0.030" Diaphragm Thickness

0

10

20

30

40

50

60

0 50 100 150 200 250 300 350

Pressure (PSI)

Out

put (

mV)

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Technology Advantages -Signal Integrity

Engineering Inc.


Bokam

0

20

40

60

80

100

120

140

160

0 50 100 150 200 250 300 350 400 450 500

Pressure (psi)

Out

put (

mV)

8/27/2004 20

Mechanical Interface Innovations

Addition of compliant elements to force sensor create a position proportional device without degradation in sensor configuration or performance

Engineering Inc.


Bokam

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8/27/2004 21

Modular System Approach

Two Axis Force Sensor

Force Proportional

Input Mechanism

Position Proportional

Input Mechanism

Analog Output

Switch Output

Cursor Control Output

(PS2/RS232)

CAN

USB

4-20 ma

Conventional Joystick Package

Submersible or Hermetic

Package

Miniature Package

Other Additional Bokam Input Devices

With Associated Electronics

Two Axis Force Sensor

Three Axis Force Sensor

Other Additional Conventional Input Devices/Switches

System Embedded

Package

Engineering Inc.


Bokam

8/27/2004 22

Signal Processing

Engineering Inc.


Bokam

Force Sensor S igna l Am plifierMicroprocessor

Output Converter

* Dead Ba nd* Span* Cru ise Control* Dynam ic Stab ility* Switch ing Funct iona lity

* Ana log Outpu t* CAN* USB* PWM* Switch ing* 4 -2 0 m A

* Num ber of Axis* Ha nd/ Finger/ Foot* Mechanica l P acka ge* Input Mecha nism

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Products - The Dome

Engineering Inc.


Bokam

8/27/2004 24

The Gadol Joystick

Engineering Inc.


Bokam

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Products - Miniature Joysticks

Engineering Inc.


Bokam

8/27/2004 26

Products - The Neptune Series

Engineering Inc.


Bokam

Non-compliant Stiff Stick InterfaceNo contacting, rubbing or optical elementsNon-magnetic construction to minimize system detectionFully submergible field tested and qualified by US NAVY for underwater use dive applicationsEmbedded strain sensor technology allows for incredible reliability and long life at continuous operation in an abusive environments

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Products - The Neptune Series

Engineering Inc.


Bokam

8/27/2004 28

Neptune Series - Systems

Engineering Inc.


Bokam

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Solid Steel Push Buttons

Engineering Inc.


Bokam

8/27/2004 30

Pedals and Foot Operated Controls

Engineering Inc.


Bokam

• Position Proportional

• Force Sensor Based

• Redundant Springs

• Fail-to-off configuration

• Adaptable to standard pedals

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Products - Embedded Systems

Engineering Inc.


Bokam

8/27/2004 32

The Bokam Advantage

• High Precision of movement

• High reliability and life in excess of 10,000,000 cycles

• Resistance to environmental exposure

• Modular system configurations and interfaces

• Force and position proportional interfaces in the same package size

• Diver proven devices

• Extensive Heritage of force sensors and input devices

• Cost effective

Engineering Inc.


Bokam

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Applications

• Diver Input Devices and Cursor Control

• Fire and guidance control

• Fly-by-wire

• Remote vehicle controls

• On-board vehicle controls

Engineering Inc.


Bokam

Documents

Jane Kamentser - White Sands Missile Range Workshops...Technology Advantages Disadvantages Potentiometers • Industrial versions available in low cost packages (military versions