Next-Generation Optimized Joystick for Construction Equipment

Abstract

This thesis presents the development of a next-generation single-lever joystick for wheel loaders, focusing on improved ergonomics, functionality, and manufacturability. The lack of significant updates since the introduction of Volvo’s original single-lever system in 2012 has created a need for a modernized joystick solution that addresses current demands for improved ergonomics, functionality, and compatibility with operator requirements. The project aimed to develop a new concept for a joystick in collaboration with CPAC Systems and targets improved user experience and suited for the operator needs. The outcome of this thesis is a fully developed joystick concept, accompanied by technical documentation. This includes detailed CAD models, manufacturing considerations, and button selection, among other elements—all of which provide a solid foundation for continued development and industrial implementation. Both FEA and DOE were conducted, ensuring that an optimized design was achieved. Joystick prototypes and a test rig were manufactured for further testing and evaluation