Control levers that can be operated by hand or with individual fingers have now found their way into a wide range of applications and industries. But not all joysticks are the same. How do they differ and what makes a good joystick? In our overview article, we look at the functionalities, design and operability of industrial joysticks.

Joysticks are not only found in the gaming world, but have long since made the leap into industrial applications. The control element helps to carry out movements more precisely and smoothly. Joysticks are widely used in crane technology, industrial trucks and agricultural machinery, drones, cable hoists and drilling platforms. Joysticks are also increasingly being integrated in plant engineering and robotics, as well as in medical technology, e.g. surgical robots.

Visit Althen Controls

Joystick for intuitive movement control

Alternatives to joystick operation are buttons, both mechanical and so-called membrane keypads, which consist of several membranes and trigger the closing of a circuit and thus a function when pressed. Joysticks are much more reactive and precise than keyboards. If, for example, a vertical movement on a crane is only executed by pressing a button, this is less intuitive for the operator than actually following the movement with a joystick.

Sensitivity and haptics are crucial

Joysticks are therefore always in demand when real movements of machines or vehicles need to be accompanied one-to-one on a small scale. A good joystick is characterised on the one hand by fine control sensitivity and on the other hand must fit well in the hand for the respective application. This is no trivial matter, as the operator will only be able to use the joystick reliably if the haptics and operability are suitable for the respective process.

Wide range of configuration options

The variety of joysticks is immense. There are basically two types of function: Hand joysticks are usually equipped with a potentiometer for control, while the more modern mini thumb or finger joysticks work with contactless sensor technology via Hall sensors. This makes them particularly durable, as the technology significantly reduces mechanical wear. A special type of hand joystick are the Cobra joysticks (named after their snake-like design), which have been tried and tested over many years and also contain push-button switches for more complex functions, for example. There is also a wide range of configuration options in terms of the number of axes, head shape, design, materials, interfaces, additional functions using buttons or similar, protection classes or industry-specific versions and environmental conditions (e.g. with ATEX certification).

Be sure to test samples

Due to the large number of configuration options, apart from a detailed requirements sheet, sampling joysticks is the key to customer enquiries for our control experts. It is important to get a feel for the device and to assess it both functionally and ergonomically. If an operator is constantly using the joystick, it must fit comfortably in the hand and not strain it. Companies that want to switch to joystick operation can use this active trial and error to convince their staff to make the switch from familiar button systems to joystick control.

High accuracy

Switching means a certain investment, as joysticks are more expensive than button systems. However, they score points for their greater precision and finer control. Depending on the application, it is not necessary to use the most sophisticated model - the joystick must always be suitable for the application. For example, a simple uniaxial Hall sensor joystick may also be suitable for controlling a hoof trimming machine for cattle.

Delivery capability and spare parts service

Our joysticks are particularly durable and are configured precisely for the respective application based on the specification. Another important criterion for customer enquiries is the ability to deliver. We deliver fully configured joysticks within two to three weeks and provide technical support if required. A spare parts service is also possible - although this is only worthwhile for higher-quality models. Simple joysticks are completely replaced in the event of wear or malfunction. However, this also depends on the environmental conditions. In the example from livestock farming, the rubber sleeves of the simple joysticks on the hoof trimming crush must be replaced regularly, as aggressive environmental conditions prevail (animal faeces) and the sleeves wear out quickly. Replacing the entire joystick would be too cost-intensive.

Precise and proportional control

Depending on the intensity and direction of the movement, the speed or position of a machine can be precisely adjusted - particularly useful when controlling machines with complex movements (e.g. cranes, robot arms).
Multidirectional control

Joysticks can control movements in several dimensions (X, Y and sometimes Z axes) simultaneously, which makes it easier to operate machines with complex freedom of movement requirements.
Combined controls

In many cases, joysticks can control several actions simultaneously, e.g. the simultaneous rotation and movement of a robot arm. This saves time and increases efficiency.
Flexibility and adaptability

Joysticks can often be individually programmed or configured to perform certain actions or meet specific requirements.

A perfect fit for every application

Joysticks can be used to control industrial motion sequences precisely and intuitively. As every application has very individual requirements, the configuration options for joysticks are also diverse. In a follow-up blog post, we will show you what is important when choosing a joystick and why haptics are particularly important.

Visit Althen Controls