Joystick Calibration

ModnyCo developed a specialized Windows software for calibrating custom joysticks, equipped with 3D handles and multiple control knobs, used in robotic systems. This software interacted with the joystick’s microcontroller, guiding operators through a series of calibration tasks with visual instructions. It efficiently processed raw data to ensure consistent joystick performance, storing calibrated settings in the EEPROM.

  • Developed Windows-based calibration software for custom joysticks used in robotic systems.
  • Provided instructive, visual-guided software interface for operators to perform calibration tasks.
  • Captured raw data from joystick during calibration, transmitting it to the software.
  • Derived non-linear conversion models, from the recorded raw data, to ensure consistent joystick behaviour, stored in the microcontroller's EEPROM.
  • Designed software to be adaptable with Excel sheets, allowing the client to modify calibration instructions independently.
  • Enabled the client to create different joystick variations for other products using the same software with varied instruction sets.

ModnyCo was presented with an intriguing challenge by a customer: to develop software for calibrating custom joysticks used to control robotic systems. These joysticks were not ordinary; they featured a 3D handle for three-axis operation and four absolute knobs for additional control, all powered by linear potentiometers. The task was to ensure each joystick delivered consistent performance before reaching the end-user.
We set out to create a Windows-based software solution that could connect to the joystick via USB. This software was designed to communicate effectively with the joystick's onboard microcontroller's firmware. The user interface of the software was crucial – it had to be intuitive and instructive. We achieved this by incorporating a series of clear instructions accompanied by visual aids. These instructions guided the operator through various calibration tasks, like moving the joystick to its limits and adjusting the knobs to their extreme positions.

As these tasks were performed, the joystick's firmware captured the raw data and transmitted it back to the Windows software. This data was critical in the calibration process. At the end of these tasks, our software undertook the complex job of training multiple non-linear conversion models. These models were then transferred back to the joystick's firmware to be stored in the microcontroller's EEPROM. This step ensured that every joystick, once turned on, would operate with consistent behaviour, a crucial factor for the precision required in controlling robotic systems.

A unique aspect of our software was its flexibility. We developed it in such a way that the client could use an Excel sheet to define the calibration instructions. This feature provided them with the autonomy to alter the calibration process without needing extensive support from ModnyCo. It proved to be a significant advantage for the client, allowing them to create different variations of the joystick for other products. They could simply use different Excel instruction sets with the same software, adapting it to the specific calibration needs of each joystick variation.

This project was a perfect example of ModnyCo's ability to deliver tailored software solutions that not only meet specific technical requirements but also provide flexibility and ease of use for the client. By integrating intuitive software with precise calibration mechanisms, we ensured that each joystick was perfectly tuned for optimal performance, reflecting our commitment to quality and innovation in software development.

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