Passive pedal force simulator with coil spring

Abstract

The present disclosure relates to a pedal assembly comprising: a pedal arm configured to move based on a load applied thereon; and a housing comprising: a first housing member having: a first cavity; and a push rod operably connected to the pedal arm and the first housing member. A first stent is positioned within the first lumen. The first bracket includes a second lumen. A first pair of springs is positioned to extend within the second cavity. The second housing member has a third cavity. A second pair of springs is positioned to extend within the second cavity and the third cavity. When a first predetermined load is applied to the pedal arm, the push rod moves, which drives the first bracket to abut against the first pair of springs, such that compression generated by at least the first pair of springs can generate a first force feedback to the pedal arm.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This patent application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 402,714, filed on August 31, 2022, and entitled “Passive Pedal Force Emulator Having Coil Springs,” the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present description relates generally to pedal assemblies for vehicles and, more particularly, to passive force simulators based on pedal movement. Background Art

[0004] Many braking systems are passively powered. However, newer braking systems now utilize electronic power-assisted braking systems, in which the assist for the braking system is provided by an electric motor to provide active force to the braking system. As a result, the need for the operator to mechanically brake is decreasing, and instead the need for the system components of the braking system to perform braking on behalf of the operator is increasing. When the braking mechanism switches, the operator still needs to receive resistance feedback when deploying the brake pedal in order to sense the degree of braking force actually being applied. In other words, despite the progress made in moving to motors to assist in stopping a vehicle, there is still a need for a passively powered simulator to provide the operator with a tactile sensation when the pedal is depressed. Summary of the invention

[0005] A first aspect of the present disclosure, alone or in combination with any other aspect herein, relates to a simulator assembly, comprising: a pedal assembly, the pedal assembly comprising: a pedal arm, which is configured to move based on a load applied thereto; a housing, which comprises: a first housing member, which has: a first cavity; and a push rod, which is operably connected to the pedal arm and the first housing member; a first bracket, which is positioned in the first cavity and is operably movable in a longitudinal direction, the first bracket including a second cavity; a first pair of springs, which are positioned to extend in the second cavity; a second housing member, which has a third cavity, a portion of the first housing member and a portion of the first bracket; A portion is received in a third cavity of the second shell member to move longitudinally relative to the second shell member based on a load; a second pair of springs having a proximal end and an opposite distal end, the second pair of springs being positioned to extend within the second cavity and the third cavity so that the proximal ends of the second pair of springs are constructed to engage with the first bracket; and an end cap connected to the second shell member and having an inner surface, the distal ends of the second pair of springs being constructed to engage with the inner surface, wherein when a first predetermined load is applied to the pedal arm, the push rod moves, which drives the first bracket against the first pair of springs so that at least the compression energy generated by the first pair of springs generates a first force feedback to the pedal arm.

[0006] Aspect 2 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 1, further comprising: a second bracket positioned in the second cavity, a first pair of springs positioned to extend between the first bracket and the second bracket in the second cavity; and a second pair of springs positioned to extend in the second cavity and the third cavity and between the second bracket and the inner surface of the end cap.

[0007] A third aspect of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 2, wherein the inner surface of the end cap includes a receiving recess configured to receive and retain the distal ends of the second pair of springs.

[0008] Aspect 4 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 2, wherein, when a second predetermined load is applied to the pedal arm, the push rod moves further longitudinally, which drives the first bracket longitudinally toward the inner surface of the end cap and drives the second bracket longitudinally toward the inner surface of the first bracket at the proximal end of the first bracket.

[0009] Aspect 5 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 4, wherein, when a second predetermined load is applied to the pedal arm, the first pair of springs are compressed and the second pair of springs are at least partially compressed to generate a second force feedback to the pedal arm.

[0010] A sixth aspect of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of the fifth aspect, wherein the second predetermined load is greater than the first predetermined load and the second force feedback has a greater force than the first force feedback.

[0011] Aspect 7 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 6, wherein, when a third predetermined load is applied to the pedal arm, the push rod moves further, which further drives the first bracket longitudinally so that the first bracket abuts the inner surface of the end cap and causes the second pair of springs to be further compressed to generate a third force feedback to the pedal arm.

[0012] Aspect 8 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 7, wherein, when a third predetermined load is applied to the pedal arm, the second bracket is moved to longitudinally abut the inner surface of the first bracket at the proximal end of the first bracket.

[0013] According to a ninth aspect of the present disclosure, the third predetermined load is greater than the second predetermined load, and the third force feedback has a greater force than the second force feedback.

[0014] Aspect 10 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 1, wherein a first pair of springs are coaxially aligned so that one of the first pair of springs is positioned within the inner diameter of another of the first pair of springs; and a second pair of springs are coaxially aligned so that one of the second pair of springs is positioned within the inner diameter of another of the second pair of springs.

[0015] Aspect 11 of the present disclosure, alone or in combination with any other aspect herein, relates to a simulator assembly comprising: a pedal arm configured to move based on a load applied thereto; a housing operably connected to the pedal arm, the housing comprising: a first bracket positioned to have a cavity and to be operably movable longitudinally; a first pair of springs positioned to extend within the cavity; a housing member having a second cavity, a portion of the first bracket being received within the second cavity of the housing member to move longitudinally relative to the housing member based on the load; a second pair of springs having a proximal end and opposing distal ends, the second pair of springs being positioned to extend within the cavity and the second cavity so that the proximal ends of the second pair of springs are configured to engage with the first bracket; and an end cap connected to the housing member and having an inner surface, the distal ends of the second pair of springs being configured to engage with the inner surface, wherein, when a first predetermined load is applied to the pedal arm, the first bracket is driven against the first pair of springs so that at least compression energy generated by the first pair of springs generates a first force feedback to the pedal arm.

[0016] Aspect 12 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 11, further comprising: a second bracket positioned within a cavity of the first bracket, a first pair of springs positioned to extend within the cavity between the first bracket and the second bracket; and a second pair of springs positioned to extend within the cavity and the second cavity and between the second bracket and an inner surface of the end cap.

[0017] A 13th aspect of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of the 12th aspect, wherein the inner surface of the end cap includes a receiving recess configured to receive and retain the distal ends of the second pair of springs.

[0018] Aspect 14 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 12, wherein, when a second predetermined load is applied to the pedal arm, the first bracket moves further longitudinally toward the inner surface of the end cap, and the second bracket moves longitudinally toward the inner surface of the first bracket at the proximal end of the first bracket.

[0019] Aspect 15 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 14, wherein, when a second predetermined load is applied to the pedal arm, the first pair of springs are compressed and the second pair of springs are at least partially compressed to generate a second force feedback to the pedal arm.

[0020] Aspect 16 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 15, wherein, when a second predetermined load is applied to the pedal arm, the first pair of springs are compressed and the second pair of springs are at least partially compressed to generate a second force feedback to the pedal arm.

[0021] Aspect 17 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 16, wherein, when a third predetermined load is applied to the pedal arm, the first bracket further moves longitudinally so that the first bracket abuts the inner surface of the end cap, and the second pair of springs are further compressed to generate a third force feedback to the pedal arm.

[0022] Aspect 18 of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of aspect 17, wherein, when a third predetermined load is applied to the pedal arm, the second bracket is moved to longitudinally abut the inner surface of the first bracket at the proximal end of the first bracket.

[0023] A 19th aspect of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of the 18th aspect, wherein the third predetermined load is greater than the second predetermined load.

[0024] A 20th aspect of the present disclosure, alone or in combination with any other aspect herein, relates to the simulator assembly of the 19th aspect, wherein the third force feedback has a greater force than the second force feedback. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The embodiments illustrated in the drawings are illustrative and exemplary in nature and are not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments may be understood when read in conjunction with the accompanying drawings, in which like structures are indicated by like reference numerals, and in which:

[0026] Figure 1 schematically depicts a left hand side view of a pedal assembly according to one or more embodiments shown and described herein;

[0027] Figure 2 Schematically depicts a Figure 1 a right hand side view of the pedal assembly;

[0028] Figure 3 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 1 The line 4-4 is intercepted Figure 1 a cross-sectional view of a pedal assembly;

[0029] Figure 4 Schematically depicts a Fig.11 an exploded view of a first embodiment of a simulator assembly of a pedal assembly;

[0030] Figure 5 Schematically depicts a diagram taken from line 4-4 with a first predetermined force applied to a pedal pad according to one or more embodiments shown and described herein. Figure 1 A cross-sectional view of a first embodiment of a simulator assembly of a pedal assembly;

[0031] Figure 6 Schematically depicts a pedal pad according to one or more embodiments shown and described herein when a second predetermined force is applied to the pedal pad. Figure 5 A cross-sectional view of a first embodiment of a simulator assembly;

[0032] Figure 7 Schematically depicts a pedal pad according to one or more embodiments shown and described herein when a third predetermined force is applied to the pedal pad. Figure 5 A cross-sectional view of a first embodiment of a simulator assembly;

[0033] Figure 8 schematically depicts an illustrative example graph of pedal travel versus applied force according to one or more embodiments shown and described herein;

[0034] Fig. 9 schematically depicts an illustrative example graph of pedal travel versus hysteresis force according to one or more embodiments shown and described herein;

[0035] Fig.10 Schematically depicts a diagram taken from line 4-4 with a first predetermined force applied to a pedal pad according to one or more embodiments shown and described herein. Figure 1 a cross-sectional view of a second embodiment of a simulator assembly of a pedal assembly;

[0036] Fig.11 Schematically depicts a pedal pad according to one or more embodiments shown and described herein when a second predetermined force is applied to the pedal pad. Fig.10 a cross-sectional view of a second embodiment of a simulator assembly;

[0037] Fig.12Schematically depicts a pedal pad according to one or more embodiments shown and described herein when a third predetermined force is applied to the pedal pad. Fig.10 a cross-sectional view of a second embodiment of a simulator assembly;

[0038] Fig.13 Schematically depicts a Figures 10 to 13 illustrative example graph of stack spring force of a second embodiment of a simulator assembly;

[0039] Fig.14 schematically depicts a third embodiment of a simulator assembly according to one or more embodiments shown and described herein;

[0040] Fig.15 Schematically depicts a partially compressed state according to one or more embodiments shown and described herein. Fig.14 A partial cross-sectional view of a simulator assembly;

[0041] Fig.16 schematically depicts a second aspect of a coil spring according to one or more embodiments shown and described herein; and

[0042] Fig.17 Schematically depicts a schematic diagram of a device in various compressions according to one or more embodiments shown and described herein. Fig.16 An illustrative example graph of a second aspect of a coil spring. DETAILED DESCRIPTION

[0043] A brake pedal emulator (BPE) is an integral device that replaces a conventional brake pedal and other hardware of an internal combustion engine and is used on electromechanical brake systems in which there is no direct mechanical or hydraulic connection between the brake pedal and the caliper. The BPE inputs are typically the force and travel distance of the pedal from the driver's foot, the reference voltages of all sensors, the grounding of all sensors, and the reaction loads at all fastening points. The resulting BPE outputs include force feedback and / or resistance of the driver's foot as a function of travel and speed, multiple pedal position sensor outputs as a function of travel, and error codes associated with the sensor outputs. Optional functions include matching or closely matching the output signal of the vehicle, the driver's expected braking input signal, or an expected braking rate that is directly or nearly directly related to the speed and force with which the driver depresses the brake pedal. The purpose is that the BPE behaves as close to a conventional braking system as possible for the driver in terms of pedal feel and deceleration performance.

[0044] The BPE may be located in the passenger compartment in the driver's footwell area. The BPE needs to meet the same mechanical loads as a conventional pedal assembly and must function in a similar manner to a conventional pedal. For example, when considering applied load, lateral load, reverse load in relation to deflection and plastic deformation, the BPE needs to behave similarly to a conventional pedal.

[0045] Conventional brake pedal assemblies include a pedal mounting bracket with a pivotally attached pedal arm / lever that has certain pedal force characteristics that need to be met during the application stroke of the pedal. Therefore, the BPE needs to be constructed to meet these same certain pedal force characteristics. Further, in some embodiments, the BPE may also include a bottom dead center for the brake pedal stroke. Additionally, the BPE needs to be constructed to withstand emergency braking loads.

[0046] The BPE assembly disclosed herein meets the following criteria: The BPE function fails such that in the event of any failure, the driver is allowed to operate the brake system by applying the pedal and an appropriate sensor signal output is provided. The BPE is constructed to withstand the foreseeable conditions and abuse to which the pedal will be subjected. The BPE is scalable to automotive mass series production and is cost effective to manufacture and assemble.

[0047] The present disclosure provides a pedal simulator system that uses a spring or a series of springs to provide resistance that allows a user to feel a sensation similar to or equal to that expected when depressing a brake pedal of a hydraulic system. In some aspects, the system includes a simulator module and a sensor adapted to sense the position and / or force of a pedal pad. The simulator is configured to simulate a brake fluid system such as a hydraulic system.

[0048] As used herein, the term "longitudinal" refers to the front-to-back direction of a component (i.e., Figure 1 The term "lateral" refers to the direction across the component (i.e., the + / -X direction depicted in FIG. Figure 1 The term "vertical" or "below" or "above" refers to the up-down direction of a component (i.e., Figure 1 + / -Z direction depicted in ).

[0049] As used herein, the term "communicatively coupled" means that the connected components are capable of exchanging data signals and / or electrical signals with each other, for example, electrical signals via a conductive medium, electromagnetic signals via the air, optical signals via an optical waveguide, electrical energy via a conductive medium or a non-conductive medium, wirelessly and / or data signals via a conductive medium or a non-conductive medium, etc.

[0050] General Reference Figures 1 to 4, schematically depicting a pedal assembly 10. The pedal assembly 10 includes a housing 12, a pedal arm assembly 14, and a first example simulator assembly 200. The pedal arm assembly 14 includes a pedal arm 18, which includes a pedal pad end 20a and a pivot end 20b. Further, the pedal arm 18 includes a first surface 74a, an opposing second surface 74b, and a pair of side surfaces 74c, 74d that define the thickness of the pedal arm 18. The pivot end 20b is pivotally coupled to the housing 12 about a pivot axis P1 in the direction indicated by arrow A1. The pedal pad end 20a receives a pedal pad 22 that a user's foot will depress to brake, accelerate, and / or initiate a clutch control.

[0051] The pedal arm assembly 14 is movably coupled to the housing 12 at the pivot end 20b, thereby allowing the pedal arm assembly 14 to move relative to the housing 12, such as by pivoting or rotating. The pedal arm assembly 14 includes a connection device 27 for connecting the push rod 28 or other connection device of the first example simulator assembly 200 to the pedal arm 18. The connection device 27 may include an elongated member 27a, a bushing 27b, and / or a retainer 27c, which is configured to be positioned in the hole 29 of the push rod 28 at the proximal end of the pedal arm 18 to connect the first example simulator assembly 200 to the pedal arm 18. Therefore, the connection device 27 can be a fastener, such as a bolt and nut, a screw, a rivet, a welded node, an epoxy resin, an adhesive, etc. The housing 12 can also accommodate, hold, or otherwise provide a connection portion for the first example simulator assembly 200. When the pedal arm assembly 14 moves in response to pressure applied by the user, the movement at the pivot end 20b in the direction of arrow A1 about P1 allows the push rod 28 to move further into the housing 12 in the longitudinal direction (i.e., + / -X direction). As explained in more detail herein, the push rod 28 is operably connected to the first example simulator assembly 200. In some aspects, the pedal arm assembly 14 may include a protrusion 31, which is configured as a stop arm to contact an elastic body 31a housed in a recess 31b of the housing 12 and stop the user's movement of the pedal arm assembly 14 after a predetermined force is applied. Therefore, travel in the longitudinal direction (i.e., + / -X direction) will stop.

[0052] The pedal arm 18 may be a molded plastic. For example, the pedal arm 18 may be formed from a variety of materials, such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high density polyethylene, low density polyethylene, polystyrene, PEEK, POM (acetal / dellin), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, and the like. Additionally, additives may be added, such as UV absorbers, flame retardants, colorants, glass fibers, plasticizers, and the like. In other embodiments, the pedal arm 18 may take any shape, whether regular or irregular, and may be formed by injection molding techniques, additive manufacturing techniques (e.g., 3D printing), and the like.

[0053] The housing 12 may include a pair or two outer sidewalls 25a, 25b with a cavity 30 therebetween. The pedal arm assembly 14 is fed into the cavity 30 and connected to the inner surfaces 25c, 25d of the outer sidewall 25b to establish the pivot end 20b. It should be understood that in some aspects, the pivot end 20b may be established with either or both of the sidewalls 25a or 25b. In some aspects, the housing 12 is a single unit. In other aspects, the housing 12 is assembled from two or more pieces.

[0054] In some aspects, the housing 12 includes two connector assemblies formed within the upper wall portion 90. In some aspects, the upper wall portion 90 is defined by two distinct wall portions 91, 92. Each wall portion 91, 92 can help retain or otherwise lock the pivot end 20b of the pedal arm 18 into the housing 12 so that the pivot end 20b pivots or moves about the wall portions 91, 92. Each of the two distinct wall portions 91, 92 can be received by a recessed portion 32 of the inner surface 25c, 25d of the side walls 25a, 25b, respectively, to retain or otherwise hold the wall portions 91, 92 in place. Each wall portion 91, 92 can provide a cover or top wall over the cavity 30 of the housing 12. Further, the upper wall portion 90 can be removable relative to the side walls 25a, 25b of the housing 12.

[0055] The housing 12 may include a first sensing assembly 42 for detecting movement of a connector 40 positioned at the pivot end 20b of the pedal arm 18 using inductive sensing technology. In some embodiments, the first sensing assembly 42 is positioned to at least partially merge with the wall portion 92, which may include a printed wiring assembly 44 and a connector housing 46. The printed wiring assembly 44 may include a circuit board 48 (or printed circuit board), which may include at least one receiver coil 50, a transmitter coil 52, and a plurality of terminal pins 54 extending therefrom. The connector 40 may be mounted or attached to the pivot end 20b of the pedal arm 18 near and perpendicular to the pivot axis Pl. Thus, the connector 40 may be positioned adjacent to the at least one receiver coil 50. In some embodiments, the connector 40 may include different petals 56, such as Figure 4 This is non-limiting, and the coupling 40 may have more or fewer lobes, may be circular or other shapes, such as half-moon, square, rectangular, etc. The coupling 40 may rotate or pivot under a load applied to the pedal pad 22, which causes the pedal arm 18 to move or pivot.

[0056] At least one receiver coil 50 and a transmitter coil 52 can detect movement of the coupling 40, and the data is transmitted to an electronic control unit and / or a powertrain controller, which is communicatively coupled to the first sensing assembly 42 via a plurality of terminal pins 54 extending within the connector housing 46. Portions of the first sensing assembly 42 can be overmolded to encapsulate electronic components, such as Figure 4 The wall portion 92 in FIG. 4 is best illustrated and may include a solderless connection between the printed wiring assembly 44 and a plurality of terminal pins 54 (such as compliant through-hole pins).

[0057] The housing 12 may also include a second sensing assembly 60 for detecting movement at the pivot end 20b of the pedal arm 18 and positioned to at least partially merge with the wall portion 91. In some aspects, the second sensing assembly 60 is provided for detecting movement of the magnet 62 using Hall effect technology. In some embodiments, the second sensing assembly 60 includes a printed wiring assembly 64 and a pair of connector housings 66a, 66b that can be incorporated into the wall portion 91. The printed wiring assembly 64 may include a circuit board 68, which may include at least one Hall effect chip 70 and a plurality of terminal pins 72 extending therefrom. The at least one Hall effect chip 70 is sensitive to Hall effect detection of magnetic changes and converts a displacement or angle measurement of a coupling member such as the magnet 62 into an electronic or electromagnetic signal. This information is transmitted to the electronic control unit and / or the powertrain controller via the plurality of terminal pins 72 for processing.

[0058] The magnet 62 can be mounted or attached to the second side 74c of the pedal arm 18 at the pivot end 20b near and perpendicular to the pivot axis P1. Thus, the magnet 62 can be positioned adjacent to at least one Hall effect chip 70. In some embodiments, the magnet 62 can be generally circular, such as Figure 4 In other embodiments, the magnet 62 may be a variety of other shapes, such as rectangular, square, hexagonal, octagonal, etc. The magnet 62 may rotate or pivot when the pedal pad 22 of the pedal arm 18 moves.

[0059] At least one Hall effect chip 70 detects movement of the magnet 62, and this data is transmitted via a plurality of terminal pins 72 extending within the connector housings 66a, 66b to an electronic control unit and / or powertrain controller communicatively coupled to the second sensing assembly 60. Portions of the second sensing assembly 60 may be overmolded to encapsulate the electronic components, and it may include solderless connections between the printed wiring assembly 64 and a plurality of terminal pins 72, such as compliant through-hole pins.

[0060] It should be appreciated that the first sensing assembly 42 and the second sensing assembly 60 simultaneously measure the movement of the pivot end 20b of the pedal arm 18 so that redundant sensing can occur. Further, the redundant sensing described herein uses different sensing techniques that provide more robust redundant sensing than conventional systems.

[0061] In the depicted embodiment, the housing 12 is configured as a suspension assembly to be mounted to the vehicle spaced apart from the floor surface of the vehicle. In other embodiments, the housing 12 can be floor mounted. That is, in some embodiments, the housing 12 can be coupled or mounted to be positioned within or extend from the floor surface of the vehicle.

[0062] Reference now Figures 3 to 7 , the first example simulator assembly 200 includes a housing 212 through which the push rod 28 can move linearly in the longitudinal direction (i.e., + / -X direction). Positioned within the housing 212 are a first bracket 201, a first spring 202, a first redundant spring 203, a second bracket 210, a second spring 220, a second redundant spring 221, and an end cap 215. As discussed in more detail herein, this is non-limiting, and in additional embodiments, the first example simulator assembly 200 may include a third spring and / or an elastomer.

[0063] The first bracket 201 can include an outer surface 201a and an opposing inner surface 201b at the proximal end 240a, and can be open or have no surface at the distal open end 240b that can be surrounded by a rim or lip 201c. That is, the rim or lip 201c can circumferentially surround the distal open end 240b so that there is a cavity 242 defined by the inner surface 201b extending from the distal open end 240b to the proximal end 240a. As shown, the outer surface 201a can face and, depending on the load applied to the pedal, can abut the inner surface 33 of the push rod 28, so that the push rod 28 defines or forms a first housing member 214 or plunger, as discussed in more detail herein.

[0064] That is, the housing 212 may include a first housing member 214 and a second housing member 216 and an end cap 215. The end cap 215 may include a sidewall 217 that is curvilinear to house or receive at least a portion of the second housing member 216 within a cavity 250 that may be defined by an inner surface 252a that is opposite an outer surface 252b of the sidewall 217. The inner surface 252 may also include at least one receiving recess 264 and an aperture 266 that extends through the recess to provide access to the cavity 257 of the second housing member 216, as discussed in greater detail herein.

[0065] The second housing member 216 may include a distal end 216a and an opposite proximal end 216b, wherein the distal end 216a is located closest to the inner surface 252a of the end cap 215. Further, the second housing member 216 includes an outer surface 256a and an opposite inner surface 256b and a cavity 257 extending between the distal end 216a and the proximal end 216b. The outer surface 256a of the second housing member 216 abuts, engages, or may otherwise communicate with a portion of the inner surface 252a of the sidewall 217 of the end cap 215.

[0066] The distal end 216a of the second housing member 216 contacts the inner surface 252a of the end cap 215. The first housing member 214 is configured to move or fold into the second housing member 216 in the longitudinal direction (i.e., + / -X direction) based on the amount of force applied to the pedal arm 18, as discussed in more detail herein. The annular ring 230 can be positioned circumferentially around the first housing member 214 to inhibit or prevent the first housing member 214 and the second housing member 216 from separating. Optionally, in the depicted embodiment, the friction ring 231 can be positioned circumferentially around a portion of the inner surface 256b between the annular ring 230 and the edge or lip 201c of the distal open end 240b of the first bracket 201 to add further resistance between the first housing member 214 and the second housing member 216 when the first housing member 214 is folded into the second housing member 216. The friction ring 231 can be tapered or angled. The friction ring 231 may be formed of a rubber material, an elastomeric material, an epoxy resin, or the like.

[0067] The first spring 202 includes a proximal end 202a and a distal end 202b and an inner diameter ID1. The second bracket 210 includes a proximal end 210a and an opposite distal end 210b. The flange 210c extends from the proximal end 210a and can be circumferential to surround the proximal end 210a. The second bracket 210 also includes an outer surface 210d and an opposite inner surface 210e. The cavity 210f extends from the proximal end 210a to the distal end 210b and is defined by the inner surface 210e, and the flange 210c can be defined by the outer surface 210d. The distal end 203b of the first spring 202 can abut, engage or otherwise contact with the inner surface 210e at the distal end 210b of the second bracket 210. The proximal end 202a of the first spring 202 can abut, engage or otherwise contact with the inner surface 201b at the proximal end 240a of the first bracket 201. The protrusion 210g may extend from the outer surface 210d at the distal end 210b, and the protrusion 210g may include an aperture 248 that allows access to the cavity 210f.

[0068] The first redundant spring 203 includes a proximal end 203a and a distal end 203b and has a diameter OD1. The diameter OD1 of the first redundant spring 203 is smaller than the inner diameter ID1 of the first spring 202, so that the first redundant spring 203 is received in the inner diameter ID1 of the first spring 202, so that the first spring 202 and the first redundant spring 203 are coaxially aligned, thereby providing a first pair of springs. The proximal end 203a of the first redundant spring 203 is similarly configured to abut, engage or otherwise contact with the inner surface 201b at the proximal end 240a of the first bracket 201. The distal end 203b of the first redundant spring 203 can similarly abut, engage or otherwise contact with the inner surface 210e at the distal end 210b of the second bracket 210.

[0069] The second bracket 210 can independently move or float within the cavity 242 between the distal open end 240b and the proximal end 240a, depending on the amount of force applied from the pedal arm 18 to the push rod 28, as discussed in more detail herein. Thus, the second bracket 210 can be positioned to slidably engage or otherwise move, ride, or similarly abut against the inner surface 201b of the first bracket 201. In some embodiments, the outer surface 210d of the flange 210c of the second bracket 210 can slidably engage, or otherwise move, ride, etc., with the inner surface 201b of the first bracket 201.

[0070] The second spring 220 includes a proximal end 220a and an opposite distal end 220b and an inner diameter ID2. The second redundant spring 221 similarly includes a proximal end 221a and an opposite distal end 221b and has an outer diameter OD2. The outer diameter OD2 of the second redundant spring 221 is smaller than the inner diameter ID2 of the second spring 220, so that the second redundant spring 221 is received in the inner diameter ID2 of the second spring 220, so that the second spring 220 and the second redundant spring 221 are coaxially aligned.

[0071] The proximal end 220a of the second spring 220 is configured to abut, engage, or otherwise contact the outer surface 210d of the flange 210c of the second bracket 210. The proximal end 221a of the second redundant spring 221 is configured to abut, engage, or otherwise contact the outer surface 210d of the distal end 210b of the second bracket 210, thereby providing a second pair of springs. In some embodiments, the proximal end 221a of the second redundant spring 221 can be coaxially aligned with the protrusion 210g extending from the outer surface 210d of the distal end 210b of the second bracket 210, so that the proximal end 221a of the second redundant spring 221 circumferentially surrounds the protrusion 210g. The distal end 220b of the second spring 220 and the distal end 221b of the second redundant spring 221 can be received by at least one receiving recess 264 of the inner surface 252a of the end cap 215.

[0072] Therefore, the second spring 220 may be completely located within the first bracket 201. The first spring 202 and the first redundant spring 203 may be completely located within the second bracket 210. The second redundant spring 221 may be compressed between the second bracket and the end cap 215.

[0073] As discussed herein, housing 212 includes a first housing member 214, which is configured to be telescopically positioned to move longitudinally (i.e., in the + / -X direction) relative to a second housing member 216. Push rod 28 is telescopically positioned to be communicated with first housing member 214. In some aspects, housing 212 includes two, three or more springs. In some aspects, each spring is provided as a pair of springs, wherein each spring includes its duplicate spring energy (e.g., kinetic energy and / or potential energy). For example, first spring 202 can have a first redundant spring 203, which is either placed in the coil of first spring 202, or placed around the coil of first spring 202, or positioned near first spring 202. There is a redundant spring to provide the same function as its duplicate and / or redundant spring. Second redundant spring 221 will therefore correspond to second spring 220, and third duplicate spring (not shown) will correspond to third spring, and so on. It should be understood that redundant springs are included as a failure protection for the first example simulator assembly 200.

[0074] Therefore, the redundant spring will compress with the same characteristics as the spring that it duplicates and / or is redundant. That is, the first redundant spring 203 compresses with the same force as the first spring 202 and outputs the same compression energy, and so on. Therefore, when the user applies force to the pedal arm 18 of the first example simulator assembly 200, the first spring 202 and the first redundant spring 203 can be equally compressed and output similar compression energies. Further, in the case where the first spring 202 is damaged, such as by material failure or fracture, the first redundant spring 203 remains in place to allow the first example simulator assembly 200 to perform in a desired manner.

[0075] Reference now Figure 5 , when stationary, and / or when a first predetermined force is applied to the pedal arm 18, the first spring 202 and the second spring 220 are able to apply an outward force as long as the first spring 202 and the second spring 220 do not allow equilibrium to be achieved therein. The push rod 28 engages the first housing member 214 to telescopically travel into the second housing member 216 in the longitudinal direction (i.e., + / -X direction). In operation, when the driver applies a first predetermined load to the pedal pad 22, the push rod 28 is linearly actuated in a generally longitudinal direction (i.e., + / -X direction), wherein the pressure or force by the first spring 202 and the first redundant spring 203 abuts against the inner surface 210e at the distal end 210b of the first bracket 201. When the first spring 202 is compressed in the longitudinal direction (i.e., + / -X direction), the first bracket 201 moves in the longitudinal direction (i.e., + / -X direction) to generate a first force feedback, such as Figure 8 The brackets in 801 are examples.

[0076] Reference now Figure 6In some embodiments, when a second predetermined load is applied to the pedal pad 22, the second bracket 210 further moves in the longitudinal direction (i.e., + / -X direction) within the coil of the second spring 220 through the proximal end 220a and the second redundant spring 221. The outer surface 210d of the flange 210c engages the proximal end 220a of the second spring 220 of the second bracket 210, and the outer surface 210d of the distal end 210b of the second bracket 210 engages the proximal end 221a of the second redundant spring 221. The distal end 220b of the second spring 220 and the distal end 221b of the second redundant spring 221 are positioned within at least one receiving recess 264 of the end cap 215 to engage with the at least one receiving recess 264 and / or the inner surface 252a, thereby compressing them to generate a second force feedback, such as Figure 8 The bracket 802 in is illustrated. The second predetermined load applied to the pedal pad 22 is a force or load of a greater magnitude than the first predetermined load. Further, the second force feedback generated and felt by the driver is a greater force than the first force feedback.

[0077] That is, because the first bracket 201 has been moved toward the end cap 215 in the longitudinal direction (i.e., + / -X direction) via the push rod 28, compression of the first spring 202 (and the corresponding first redundant spring 203) into the second bracket 210 is achieved. The proximal end 202a and the distal end 202b of the first spring 202 have been compressed to have lengths closer to each other (e.g., moved toward each other), as have the proximal end 203a and the distal end 203b of the first redundant spring 203. The distance between the first bracket 201 and the second bracket 210 is similarly reduced. The proximal end 220a of the second spring 220 engages with the outer surface 210d at the flange 210c of the second bracket 210. Further, the first housing member 214 telescopically moves into the second housing member 216 in the longitudinal direction (i.e., + / -X direction) with the protrusion 214a away from the annular ring 230. The first bracket 201 is also lowered longitudinally (ie, + / -X direction) into the second housing member 216 by the protrusion 214a driving the friction ring 231 on the outer edge or lip 201c of the first bracket 201. The second spring 220 and / or the second redundant spring 221 may not yet be substantially engaged.

[0078] Therefore, reference Figure 8 , the force applied to compress the first spring 202 alone is relatively low, however, when the second series of springs (e.g., the second spring 220 and the second redundant spring 221) are engaged, the load output as force feedback felt by the driver on the pedal pad 22 increases significantly, where since the compression of the first spring series (the first spring 202 and the first redundant spring 203) must be maintained, the load output is greater than compressing only the second spring series (e.g., the second spring 220 and the second redundant spring 221).

[0079] Reference now Figure 7 In some embodiments, when the third predetermined load is applied to the pedal pad 22, the second bracket 210 further moves in the longitudinal direction (i.e., + / -X direction) through the proximal end 220a and the second redundant spring 221 within the coil of the second spring 220. The outer surface 210d of the flange 210c has been engaged with the proximal end 220a of the second spring 220 of the second bracket 210 and the outer surface 210d of the distal end 210b of the second bracket 210, and engaged with the proximal end 221a of the second redundant spring 221, and further compresses the second spring 220 and the second redundant spring 221 in the longitudinal direction (i.e., + / -X direction) to generate a third force feedback, such as Figure 8 The bracket 803 in is illustrated. The third predetermined load applied to the pedal pad 22 is a force or load of a greater magnitude than the second predetermined load. Further, the third force feedback generated and felt by the driver is a greater force than the second force feedback.

[0080] Right now, Figure 7 The first example simulator assembly 200 is illustrated in full compression, wherein both the first spring 202 (and the corresponding first redundant spring 203) and the second spring 220 (and the corresponding second redundant spring 221) are fully compressed. The inner surface 201b of the first bracket 201 contacts or otherwise abuts the proximal end 210a of the second bracket, such that the outer surface 210d at the flange 210c of the second bracket 210 contacts or otherwise abuts the inner surface 201b of the first bracket 201. Further, in this position, the edge or lip 201c of the first bracket 201 contacts the inner surface 252a of the end cap 215 adjacent to the at least one receiving recess 264.

[0081] It will be appreciated that as the force applied to the pedal pad 22 decreases, the second spring 220 and the second redundant spring 221 will attempt to shift to equilibrium, thereby internally resetting the housing 212 while providing a restoring force to the pedal arm 18 .

[0082] In some embodiments, springs 202, 203, 220, 221 can be independently formed of steel material. In other embodiments, springs 202, 203, 220, 221 can be independently formed of stainless steel, wire, carbon steel, alloy steel, The housing 12 and / or the upper wall portion 90 may be formed of a variety of materials, such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / dellin), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as UV absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. may be added.

[0083] refer to Figure 8 , shows the expected force response curve for the pedal. It can be seen that as the pedal travels, the required application force becomes larger. The force is non-linear and increases significantly near the end of the pedal travel. This type of force response is commonly found in mechanical pedal designs where there is a linkage that is mechanically or hydraulically coupled to the brake caliper. When a pedal application force (PE) is applied to the pedal, the pedal arm pivots to allow the pedal to travel. The simulator applies an opposite simulator force (EF) to provide the driver with a resistance that varies depending on the speed at which PE is applied.

[0084] refer to Fig. 9 , shows a graph of the expected mechanical hysteresis according to the force as a function of the pedal position. It can be seen in the figure that the curve has Figure 8 . It is desirable to have this force response in a drive-by-wire brake system without a mechanical linkage. Such a system would include a brake pedal simulator in place of a mechanically linked brake pedal.

[0085] Reference now Figures 10 to 12 , schematically depicting a second example embodiment of a simulator assembly 400. It should be understood that, except for the features described herein, the simulator assembly 400 is similar to the simulator assembly 200. Therefore, like features of the pedal assembly will use the same reference numerals, and like features of the simulator assembly will use the same reference numerals, wherein the reference numerals have a prefix of "4". Therefore, for the sake of brevity, these features may not be described again.

[0086] The simulator assembly 400 is a three-series simulator including a first spring 402, a second spring 420, and a third spring 490. The embodiment includes a housing 412. The housing 412 includes a first housing member 414 that is configured to be telescopically movable in a longitudinal direction (i.e., + / -X direction) relative to a second housing member 416. The push rod 28 is telescopically positioned in the first housing member 414.

[0087] The first spring 402 is positioned within the first bracket 401. The proximal end 402a of the first spring 402 abuts against and / or is configured to abut, engage or otherwise contact with the inner surface 401b at the proximal end 440a of the first bracket 401. The distal end 402b of the first spring 402 abuts against and / or is configured to abut, engage or otherwise contact with the inner surface 410e at the distal end 410b in the cavity 410f. In this embodiment, the second bracket 410 can also be configured to be in an opposite orientation compared to the first bracket 401. This is non-limiting, and the second bracket 410 can be in any orientation relative to the first bracket 401.

[0088] The receiving recess 464 of the end cap 415 includes a side wall 470 extending from the inner surface 452a in the longitudinal direction (i.e., + / -X direction). The side wall 470 can be circular to define a cavity 472. This is non-limiting, and the side wall 470 can be of any shape. The cavity 472 can be configured to receive an elastomeric member 480 therein. The elastomeric member 480 can include a proximal end 482a and an opposite distal end 482b. The distal end 482b abuts, engages, or otherwise contacts the inner surface 452a of the end cap 415 within the cavity 472 of the receiving recess 464. The proximal end 482a is positioned to exceed the terminal portion of the side wall 470 in the longitudinal direction (i.e., + / -X direction).

[0089] The third bracket 484 is positioned within the cavity 457 of the second housing member 416. The third bracket includes an outer surface 486a and an opposing inner surface 486b, and may be generally shaped as a circle with a cavity 486C so as to be an inverted C-shape in cross section. This is non-limiting, and the third bracket 484 may be any shape. The protrusion 488a may extend longitudinally (i.e., + / -X direction) from the outer surface 486A, and may include an orifice 488b that allows access to the cavity 486c.

[0090] The proximal end 482a of the elastomeric member 480 can be received in the cavity 486c to separate the third bracket 484 from the terminal end of the side wall 470. Therefore, in the uncompressed state, the length of the elastic member 480 in the longitudinal direction (ie, + / -X direction) exceeds the terminal end of the side wall 470.

[0091] The second spring 420 can be positioned in the second housing member 416, wherein the second spring 420 is coaxially aligned with the protrusion 488a such that the distal end 420b of the second spring 420 circumferentially surrounds the protrusion 488a of the third bracket 484. The proximal end 420a is configured to contact, abut, or otherwise engage with an outer surface 410d of the flange 410c of the second bracket 410 depending on a load applied to the push rod 28, as discussed in more detail above.

[0092] The third spring 490 has a proximal end 490a and an opposite distal end 490b. The proximal end 490a of the third spring 450 is sized to fit around the ledge 494 and / or within a recess in the sidewall 401d of the first bracket 401. The inner diameter of the third spring 490 is large enough to circumferentially surround the third bracket 484, the sidewall 470, and the receiving recess 464 so that the distal end 490b rests, abuts, engages, or otherwise contacts the inner surface 452a of the end cap 415. Although not shown, it should be understood that all springs in this embodiment can be arranged in the same manner as described above with respect to Figures 5 to 7 The similar manner described further includes its redundant spring separately.

[0093] like Figures 10 to 12 As further shown, the housing 412 can be configured to fold. The housing 412 can include a first housing member 414, a second housing member 416, and an end cap 415. When stationary, the first spring 402 and the second spring 420 are capable of applying an outward force as long as the first spring 402 and the second spring 420 do not allow balance to be achieved therein. The push rod 28 engages the first housing member 414 to telescopically travel into the second housing member 416. In multiple aspects, the second housing member includes an annular ring 230 around the second housing member 416, which prevents the first housing member 214 from disengaging. The first housing member 414 may include a protrusion 414a that engages with the stop ring 430 of the second housing member 416. By having the protrusion 414a, the annular ring 230 captures the first housing member 414 to prevent it from disengaging. In some aspects, the housing 412 can be characterized by a friction ring 231 around the circumference or periphery of the outer edge 401c of the first bracket 401. The friction ring 431 may be tapered, as may the protrusion 414 a , thereby allowing the first housing member 414 to be moved into the second housing member 416 via the first bracket 401 .

[0094] refer to Fig.10, a cross-sectional view of another simulator assembly 400 having a three-spring arrangement therein is shown. The simulator assembly 400 includes a housing 412, which includes a first housing member 414 telescopically positioned longitudinally relative to a second housing member 416. The push rod 28 is telescopically positioned in the first housing member 414. An elastomer 480 or foam is positioned at the end of the second housing member 416 within the end cap 415. The simulator assembly 400 also includes a third spring 450 and an optional third duplicate spring (not shown). The bottom coil of the third spring rests on the end cap 415 and surrounds the base of the elastomer 480. Optionally, the elastomer 480 is housed in a third bracket 441. The proximal end 490a of the third spring 450 is configured so that when the first bracket is engaged by the push rod 28 toward the end cap 415, a ledge 494 within the side wall of the first bracket 401 can engage the top coil of the third spring 450. As depicted, the third spring surrounds the elastomer 480 and the second spring 420. It should be noted that this positioning is optional and the third spring 450 may be placed at other locations within the cavity of the housing 412 and still engage the first bracket 401 and the end cap 415 .

[0095] In operation and reference Fig.10 , when the simulator assembly 400 is activated, the push rod 28 is linearly actuated in the longitudinal direction (i.e., + / -X direction), wherein a first predetermined load is applied to the pedal pad 22, and pressure is applied to the inner surface 410e at the distal end 410b of the first bracket 401 through the first spring 402. When the first spring 402 is compressed in the longitudinal direction (i.e., + / -X direction), the first bracket 401 moves in the longitudinal direction (i.e., + / -X direction) to generate a first force feedback, such as Figure 8 The brackets in 801 are examples.

[0096] Reference now Fig.11 In some embodiments, when a second predetermined load is applied to the pedal pad 22, the first spring 402 is further compressed in the longitudinal direction (i.e., + / -X direction), and the second bracket 410 is further moved within the coil of the second spring 420 and passes through the proximal end 420a of the second spring 420 in the longitudinal direction (i.e., + / -X direction). The outer surface 410d of the flange 410c engages the proximal end 420a of the second spring 420 of the second bracket 410. The distal end 420b of the second spring 420 is positioned to engage the outer surface 486a of the third bracket 484, causing it to compress, to generate a second force feedback, such as Figure 8 The bracket 802 in is illustrated. The second predetermined load applied to the pedal pad 22 is a force or load of a greater magnitude than the first predetermined load. Further, the second force feedback generated and felt by the driver is a greater force than the first force feedback.

[0097] That is, because the first bracket 401 has been moved toward the end cap 415 in the longitudinal direction (i.e., + / -X direction) via the push rod 28, the compression of the first spring 202 into the second bracket 410 is achieved. The proximal end 402a and the distal end 402b of the first spring 402 have been compressed to have a length closer to each other (e.g., moved toward each other). The first bracket 401, the second bracket 410, and the third bracket 484 each move similarly, and the distance between each of them decreases. The proximal end 420a of the second spring 420 engages with the outer surface 410d at the flange 410c of the second bracket 410. Further, the first housing member 414 is telescopically advanced into the second housing member 416 in the longitudinal direction (i.e., + / -X direction) with the protrusion 414a away from the stop ring 430. The first bracket 401 is also lowered into the second housing member 416 in the longitudinal direction (ie, + / -X direction) by the protrusion 414a driving the friction ring 431 on the outer edge 401c of the first bracket 401. The second spring 420 may not be substantially engaged yet.

[0098] Therefore, reference Figure 8 , the force applied to compress the first spring 402 alone is relatively low, however when the second series of springs (e.g., second spring 420) is engaged, the load output as force feedback felt by the driver on the pedal pad 22 increases significantly, where the load output is greater than compressing only the second spring series (e.g., second spring 420) because the compression of the first spring series (first spring 402) must be maintained.

[0099] Reference now Fig.12 In some embodiments, when a third predetermined load is applied to the pedal pad 22, the second bracket 410 further moves within the coil of the second spring 420 through the proximal end 420a to abut the third bracket 484 in the longitudinal direction (i.e., + / -X direction), which in turn applies a force to the third bracket 484 to cause the elastomeric member 480 to fold or deform. Therefore, the outer surface 410d of the second bracket 410 abuts or engages with the outer surface 486a of the third bracket 484. Therefore, the first spring 402, the second spring 420, and the third spring 490 are all compressed in the longitudinal direction (i.e., + / -X direction), and a load is applied to the elastomeric member 480 to cause the elastomeric member 480 to fold or deform, thereby generating a third force feedback, such as Figure 8 The bracket 803 in is illustrated. The third predetermined load applied to the pedal pad 22 is a force or load of a greater magnitude than the second predetermined load. Further, the third force feedback generated and felt by the driver is a greater force than the second force feedback.

[0100] Right now, Fig.12Full compression of the simulator assembly 400 is illustrated, wherein the first spring 402, the second spring 420, and the third spring 490 are compressed and force is applied to the elastomeric member 480 by the third bracket 484. When the user removes pressure from the pedal pad 22, the first spring 402, the second spring 420, and the third spring 490 will attempt to shift to equilibrium and thereby reset the housing 412 internally.

[0101] Reference now Figure 14 to Figure 15 , schematically depicts another example embodiment of a simulator 1410. The simulator 1410 includes a spring housing 1412 attached to a surface and a push rod 1414 positioned within the spring housing 1412. The push rod 1414 moves between a plurality of positions. The push rod 1414 includes a distal end 1416 and a proximal end 1418. The proximal end 1418 includes a pedal attachment 1420 coupled to a pedal arm 1422. The pedal arm 1422 is pivotally movable about a pivot 1424. It should be appreciated that a variety of pedal and pivot positions may be used. The distal end 1416 is positioned within a chamber 1426 of the spring housing 1412. The chamber 1426 is configured to receive a plurality of springs and spring carriers, as well as the distal end 1416 of the push rod 1414.

[0102] The push rod 1414 enters the spring housing 1412 and engages the first series of springs 1428, wherein the proximal end 1418 of the push rod 1414 remains outside the spring housing 1412. In the depicted embodiment, the plurality of springs includes a first series of springs 1428, a second series of springs 1430, and a parallel third spring 1432. The chamber 1426 also receives a spring support. The spring support includes a first spring support 1434 spaced longitudinally (i.e., in the + / -X direction) from a second spring support 1436, and the second spring support is spaced longitudinally from the third spring support 1438.

[0103] Still reference Fig.15 , the spring support includes a housing surface 1440 extending to a side wall 1442, the side wall including a flange 1444 formed thereon. The housing surfaces 1440 of the first spring support 1434 and the third spring support 1438 are positioned in the chamber 1426 such that the housing surface 1440 is positioned at the top. The second spring support 1436 is positioned in the chamber 1426 such that the housing surface 1440 is positioned at the bottom. The housing surface 1440 may include a hole 1443 formed therein to allow for accommodation of a post, as will be described in more detail below.

[0104] like Fig.15As shown, the first spring bracket 1434 contacts the distal end 1416 of the push rod 1414. The parallel third spring 1432 contacts the flange 1444 of the first spring bracket 1434 and the bottom surface 1446 of the spring housing 1412. The first series spring 1428 contacts the housing surface 1440 of the first spring bracket 1434 and the second spring bracket 1436. The second series spring 1430 contacts the flange 1444 of the second spring bracket 1436 and the third spring bracket 1438. An elastomeric member 1448 or foam member is positioned between the bottom of the spring housing 1412 and the third spring bracket 1438. The elastomeric member 1448 or foam member serves as a stop for the final compression member and travel of the pedal arm 1422. In the depicted embodiment, the elastomeric member 1448 or foam member is positioned around the post of the spring housing 1412 to maintain the position of the elastomeric member 1448 or foam member. The friction member 1450 can be positioned in the spring housing 1412. The friction member 1450 may contact a portion of the push rod 1414 at the beginning of the stroke of the push rod 1414. The friction member 1450 may be made of various materials and have various shapes to affect the frictional resistance provided.

[0105] In operation, when the pedal arm 1422 is depressed by the driver, the push rod 1414 of the pedal simulator is linearly actuated, which begins to compress the parallel third spring 1432 and the first series of springs 1428. As the push rod 1414 travels further in the spring housing 1412, the second series of springs 1430 are compressed. Further travel of the push rod 1414 in the spring housing 1412 causes compression of the foam member or elastomeric member 1448.

[0106] refer to Fig.13 , the forces applied by the various springs 1428, 1430, 1432 and the foam or elastomeric member 1448 are shown as a function of travel distance. As can be seen in the figure, the various springs apply different forces at corresponding travel positions. The compression of the foam or elastomeric member 1448 applies significant force to the pedal. The combination of the various springs and the foam or elastomeric member 1448 results in a Figure 8 and Fig. 9 The forces of the desired force curve are similar to the resultant forces.

[0107] refer to Fig.16 , shows an additional embodiment including a nonlinear compression spring 312. The nonlinear compression spring 312 may be used in any embodiment of the simulator assembly described herein, and may be used in any of the various springs described herein, or may be used in other pedal assemblies where a spring force is applied to a component of the pedal assembly.

[0108] Fig.16As can be seen in FIG. 1 , spring 1612 includes a coil diameter 1614 and a coil pitch 1616 that are non-uniform along the length of spring 1612. Thus, spring 1612 will have variable force characteristics when various portions of spring 1612 are compressed. In one aspect, first end 1618 of spring 1612 may include a larger diameter and a smaller pitch angle than second end 1620 of spring 1612 that includes a smaller diameter and a larger pitch angle.

[0109] refer to Fig.17 , shows a graph of the force or load of a compression spring 1612 as a function of length. As can be seen in the figure, due to the varying diameter and pitch of the spring along its length, the force does not behave in a linear manner when the spring is compressed. The combination of varying diameter and pitch results in a linear relationship with Figure 8 and Fig. 9 The forces of the desired force curve are similar to the resultant forces.

[0110] Thus, a novel simulator system is disclosed. It will be clear to those skilled in the art that many variations are possible within the scope of the invention.

[0111] The above description of specific embodiments is merely exemplary in nature and is in no way intended to limit the scope of the invention, its application or use, which, of course, may vary. The present invention is described with respect to the non-limiting definitions and terms included herein. These definitions and terms are not designed to limit the scope or practice of the present invention, but are presented for illustrative and descriptive purposes only. Although processes or compositions are described as the order of individual steps or using specific materials, it should be understood that steps or materials may be interchangeable, so that the description of the present invention may include multiple parts or steps arranged in many ways that are readily understood by those of ordinary skill in the art.

[0112] The terms used herein are only used to describe specific embodiments and are not intended to be limiting. As used herein, the singular forms "one", "an" and "the" are intended to include plural forms, including "at least one", unless the content explicitly indicates otherwise. "Or" means "and / or". As used herein, the term "and / or" includes all combinations of one or more associated listed items. It should also be understood that when used in this specification, the terms "include" and / or "comprise" or "contain" specify the presence of the features, regions, integers, steps, operations, elements, parts and / or groups, but do not exclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, parts and / or groups thereof. The term "or a combination thereof" means a combination including at least one of the aforementioned elements.

[0113] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure belongs. It should also be understood that terms (such as those defined in commonly used dictionaries) should be interpreted as having a meaning consistent with their meaning in the context of the relevant art and the present disclosure, and should not be interpreted in an idealized or overly formal sense, unless explicitly defined as such herein.

[0114] The patents, applications and publications mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. These patents and publications are incorporated herein by reference to the same extent as if each individual application or publication was specifically and individually incorporated herein by reference.

[0115] The foregoing description is illustrative of particular aspects of the present invention and is not meant to limit the practice thereof. It is intended that the following claims, including all equivalents thereof, define the scope of the present invention.

Claims

1. A pedal assembly, comprising: a pedal arm configured to move based on a load applied thereto; A housing comprising: The first housing member has: a first cavity; and a push rod operably connected to the pedal arm and the first housing member; a first bracket positioned within the first cavity and operably movable in a longitudinal direction, the first bracket including a second cavity; a first pair of springs positioned to extend within said second cavity; a second housing member having a third cavity, a portion of the first housing member and a portion of the first bracket being received in the third cavity of the second housing member to move relative to the second housing member in the longitudinal direction based on the load; a second pair of springs having a proximal end and an opposing distal end, the second pair of springs positioned to extend within the second cavity and the third cavity such that the proximal ends of the second pair of springs are configured to engage the first bracket; and an end cap coupled to the second housing member and having an inner surface with which the distal ends of the second pair of springs are configured to engage, When a first predetermined load is applied to the pedal arm, the push rod moves to drive the first bracket against the first pair of springs, so that at least compression energy generated by the first pair of springs generates a first force feedback to the pedal arm.

2. The pedal assembly according to claim 1, further comprising: a second stent positioned within the second cavity, the first pair of springs being positioned to extend within the second cavity between the first bracket and the second bracket; and The second pair of springs is positioned within the second cavity and the third cavity and extends between the second bracket and the inner surface of the end cap.

3. The pedal assembly according to claim 2, wherein: The inner surface of the end cap includes a receiving recess configured to receive and retain the distal ends of the second pair of springs.

4. The pedal assembly according to claim 2, wherein: When a second predetermined load is applied to the pedal arm, the push rod further moves in the longitudinal direction to drive the first bracket in the longitudinal direction toward the inner surface of the end cap and drives the second bracket in the longitudinal direction toward the inner surface of the first bracket at the proximal end of the first bracket.

5. The pedal assembly according to claim 4, wherein: When the second predetermined load is applied to the pedal arm, the first pair of springs are compressed and the second pair of springs are at least partially compressed to generate a second force feedback to the pedal arm.

6. The pedal assembly according to claim 5, wherein: The second predetermined load is greater than the first predetermined load, and the second force feedback has a greater force than the first force feedback.

7. The pedal assembly according to claim 6, wherein: When a third predetermined load is applied to the pedal arm, the push rod moves further to further drive the first bracket in the longitudinal direction so that the first bracket abuts the inner surface of the end cap and the second pair of springs are further compressed to generate a third force feedback to the pedal arm.

8. The pedal assembly according to claim 7, wherein: When the third predetermined load is applied to the pedal arm, the second bracket is moved to abut against the inner surface of the first bracket at the proximal end of the first bracket in the longitudinal direction.

9. The pedal assembly according to claim 8, wherein: The third predetermined load is greater than the second predetermined load, and the third force feedback has a greater force than the second force feedback.

10. The pedal assembly according to claim 1, wherein: The first pair of springs are coaxially aligned such that one of the first pair of springs is positioned within an inner diameter of another of the first pair of springs; and The second pair of springs are coaxially aligned such that one of the second pair of springs is positioned within an inner diameter of another of the second pair of springs.

11. A pedal assembly comprising: a pedal arm configured to move based on a load applied thereto; a housing operably coupled to the pedal arm, the housing comprising: a first bracket positioned to have a cavity and to be operably movable in a longitudinal direction; a first pair of springs positioned to extend within the cavity; a housing member having a second cavity, a portion of the first bracket being received in the second cavity of the housing member to move relative to the housing member in the longitudinal direction based on the load; a second pair of springs having a proximal end and an opposing distal end, the second pair of springs positioned to extend within the cavity and the second lumen such that the proximal ends of the second pair of springs are configured to engage the first stent; and an end cap coupled to the housing member and having an inner surface with which the distal ends of the second pair of springs are configured to engage, Wherein, when a first predetermined load is applied to the pedal arm, the first bracket is driven against the first pair of springs so that at least compression energy generated by the first pair of springs generates a first force feedback to the pedal arm.

12. The pedal assembly of claim 11, further comprising: a second stent positioned within the cavity of the first stent, The first pair of springs are positioned to extend within the cavity between the first bracket and the second bracket; and The second pair of springs is positioned within the cavity and the second cavity and extends between the second bracket and the inner surface of the end cap.

13. The pedal assembly of claim 12, wherein: The inner surface of the end cap includes a receiving recess configured to receive and retain the distal ends of the second pair of springs.

14. The pedal assembly of claim 12, wherein: When a second predetermined load is applied to the pedal arm, the first bracket further moves in the longitudinal direction toward the inner surface of the end cap, and the second bracket moves in the longitudinal direction toward the inner surface of the first bracket at a proximal end of the first bracket.

15. The pedal assembly of claim 14, wherein: When the second predetermined load is applied to the pedal arm, the first pair of springs are compressed and the second pair of springs are at least partially compressed to generate a second force feedback to the pedal arm.

16. The pedal assembly of claim 15, wherein: The second predetermined load is greater than the first predetermined load, and the second force feedback has a greater force than the first force feedback.

17. The pedal assembly of claim 16, wherein: When a third predetermined load is applied to the pedal arm, the first bracket further moves in the longitudinal direction so that the first bracket abuts against the inner surface of the end cap, and the second pair of springs is further compressed to generate a third force feedback to the pedal arm.

18. The pedal assembly of claim 17, wherein: When the third predetermined load is applied to the pedal arm, the second bracket is moved to abut against the inner surface of the first bracket at the proximal end of the first bracket in the longitudinal direction.

19. The pedal assembly of claim 18, wherein: The third predetermined load is greater than the second predetermined load.

20. The pedal assembly of claim 19, wherein: The third force feedback has a greater force than the second force feedback.

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